Fitter Sem2 TP

FITTER
NSQF LEVEL - 5
2nd Semester
TRADE PRACTICAL
SECTOR: Production & Manufacturing
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DIRECTORATE GENERAL OF TRAINING

MINISTRY OF SKILL DEVELOPMENT & ENTREPRENEURSHIP
GOVERNMENT OF INDIA
NATIONAL INSTRUCTIONAL
MEDIA INSTITUTE, CHENNAI
Post Box No. 3142, CTI Campus, Guindy, Chennai - 600 032
(i)
Sector : Production & Manufacturing
Duration : 2 - Years
Trade : Fitter 2nd Semester - Trade Practical - NSQF level 5
Copyright © 2018 National Instructional Media Institute, Chennai

First Edition : November, 2018 Copies : 1,000
First Reprint : January, 2019 Copies : 5,000
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Rs. 200/- ish
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All rights reserved.

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No part of this publication can be reproduced or transmitted in any form or by any means, electronic or mechanical, including
photocopy, recording or any information storage and retrieval system, without permission in writing from the National
Instructional Media Institute, Chennai.
Published by:
NATIONAL INSTRUCTIONAL MEDIA INSTITUTE
P. B. No.3142, CTI Campus, Guindy Industrial Estate,
Guindy, Chennai - 600 032.
Phone : 044 - 2250 0248, 2250 0657, 2250 2421
Fax : 91 - 44 - 2250 0791
email : [email protected], [email protected]
Website: www.nimi.gov.in
(ii)
FOREWORD
The Government of India has set an ambitious target of imparting skills to 30 crores people, one out of every
four Indians, by 2020 to help them secure jobs as part of the National Skills Development Policy. Industrial
Training Institutes (ITIs) play a vital role in this process especially in terms of providing skilled manpower.
Keeping this in mind, and for providing the current industry relevant skill training to Trainees, ITI syllabus
has been recently updated with the help of Mentor Councils comprising various stakeholder's viz. Industries,
Entrepreneurs, Academicians and representatives from ITIs.
The National Instructional Media Institute (NIMI), Chennai has now come up with instructional material to
suit the revised curriculum for Fitter 2nd Semester Trade Practical NSQF Level - 5 in Production &
Manufacturing Sector under Semester Pattern. The NSQF Level - 5 Trade Practical will help the trainees
to get an international equivalency standard where their skill proficiency and competency will be duly
recognized across the globe and this will also increase the scope of recognition of prior learning. NSQF
Level - 5 trainees will also get the opportunities to promote life long learning and skill development. I have
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no doubt that with NSQF Level - 5 the trainers and trainees of ITIs, and all stakeholders will derive maximum
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benefits from these IMPs and that NIMI's effort will go a long way in improving the quality of Vocational
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training in the country.
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The Executive Director & Staff of NIMI and members of Media Development Committee deserve appreciation
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for their contribution in bringing out this publication.
Jai Hind
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RAJESH AGGARWAL
Director General/ Addl. Secretary
Ministry of Skill Development & Entrepreneurship,
Government of India.
New Delhi - 110 001
(iii)
PREFACE
The National Instructional Media Institute (NIMI) was established in 1986 at Chennai by then Directorate
General of Employment and Training (D.G.E & T), Ministry of Labour and Employment, (now under Directorate
General of Training, Ministry of Skill Development and Entrepreneurship) Government of India, with technical
assistance from the Govt. of the Federal Republic of Germany. The prime objective of this institute is to
develop and provide instructional materials for various trades as per the prescribed syllabi under the Craftsman
and Apprenticeship Training Schemes.
The instructional materials are created keeping in mind, the main objective of Vocational Training under
NCVT/NAC in India, which is to help an individual to master skills to do a job. The instructional materials are
generated in the form of Instructional Media Packages (IMPs). An IMP consists of Theory book, Practical
book, Test and Assignment book, Instructor Guide, Audio Visual Aid (Wall charts and Transparencies) and
other support materials.
The trade practical book consists of series of exercises to be completed by the trainees in the workshop.
These exercises are designed to ensure that all the skills in the prescribed syllabus are covered. The trade
theory book provides related theoretical knowledge required to enable the trainee to do a job. The test and
assignments will enable the instructor to give assignments for the evaluation of the performance of a trainee.
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The wall charts and transparencies are unique, as they not only help the instructor to effectively present a
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topic but also help him to assess the trainee's understanding. The instructor guide enables the instructor to
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plan his schedule of instruction, plan the raw material requirements, day to day lessons and demonstrations.
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In order to perform the skills in a productive manner instructional videos are embedded in QR code of the
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exercise in this instructional material so as to integrate the skill learning with the procedural practical steps
given in the exercise. The instructional videos will improve the quality of standard on practical training and
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will motivate the trainees to focus and perform the skill seamlessly.
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IMPs also deals with the complex skills required to be developed for effective team work. Necessary care
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has also been taken to include important skill areas of allied trades as prescribed in the syllabus.
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The availability of a complete Instructional Media Package in an institute helps both the trainer and
management to impart effective training.
The IMPs are the outcome of collective efforts of the staff members of NIMI and the members of the Media
Development Committees specially drawn from Public and Private sector industries, various training institutes
under the Directorate General of Training (DGT), Government and Private ITIs.
NIMI would like to take this opportunity to convey sincere thanks to the Directors of Employment & Training
of various State Governments, Training Departments of Industries both in the Public and Private sectors,
Officers of DGT and DGT field institutes, proof readers, individual media developers and coordinators, but for
whose active support NIMI would not have been able to bring out this materials.
R. P. DHINGRA
Chennai - 600 032 EXECUTIVE DIRECTOR
(iv)
ACKNOWLEDGEMENT
National Instructional Media Institute (NIMI) sincerely acknowledges with thanks for the co-operation and
contribution extended by the following Media Developers and their sponsoring organisations to bring out this
Instructional Material (Trade Practical) for the trade of Fitter under Production & Manufacturing Sector for ITIs.
MEDIA DEVELOPMENT COMMITTEE MEMBERS
Shri. M. Sampath _ Training officer (Retd.)

CTI, Chennai-32.
Shri. M. Sangarapandian _ Training officer (Retd.)

CTI, Chennai - 32
Shri. K. Kesavan _ Asst. App. Advisor Junior (Retd)

DET, Tamilnadu
Shri. C.C. Subramanian _ Training officer (Retd.)

Balamandir PHM ITI, Chennai - 17
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Shri. A. Stephen _ Instructor, St. John’s ITI
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Manapparai
Trichy District - 621 307
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Shri. K.B. Shivaramu _ Junior Training officer

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Government ITI, Mysore - 570007
Shri. D.C. Nataraja _ Junior Training officer

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Government ITI, Mysore - 570007

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Shri. Milind Rasu _ Instructor, Government ITI

Aliganj, Lucknow
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Shri. K. Srinivasa Rao _ Joint Director,

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Co-ordinator, NIMI, Chennai - 32
Shri. G. Michael Johny _ Assistant Manager,

Co-ordinator, NIMI, Chennai - 32
NIMI records its appreciation for the Data Entry, CAD, DTP operators for their excellent and devoted services in
the process of development of this Instructional Material.
NIMI also acknowledges with thanks the invaluable efforts rendered by all other NIMI staff who have contributed
towards the development of this Instructional Material.
NIMI is also grateful to everyone who has directly or indirectly helped in developing this Instructional Material.
(v)
INTRODUCTION
TRADE PRACTICAL
The trade practical manual is intented to be used in practical workshop . It consists of a series of practical
exercises to be completed by the trainees during the Second Semester Course of the Fitter Trade
supplemented and supported by instructions/ informations to assist in performing the exercises. These
exercises are designed to ensure that all the skills in compliance with NSQF LEVEL - 5 syllabus are covered.
The manual is divided into five modules. The distribution of time for the practical in the five modules are given
below.
Module 1 Drilling 150 Hrs

Module 2 Fitting assembly 150 Hrs
Module 3 Turning 125 Hrs
Module 4 Basic Maintenance 75 Hrs
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Module 5 Project work 50 Hrs
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The skill training in the shop floor is planned through a series of practical exercises centred around some
practical object. However, there are few instances where the individual exercise does not form a part of project.
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While developing the practical manual a sincere effort was made to prepare each exercise which will be easy
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to understand and carry out even by below average trainee. However the development team accept that there
is a scope for further improvement. NIMI looks forward to the suggestions from the experienced training faculty
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for improving the manual.

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TRADE THEORY
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The manual of trade theory consists of theoretical information for the Second Semester Course of the Fitter
Trade. The contents are sequenced according to the practical exercise contained in NSQF LEVEL - 5 syallabus
on Trade practical. Attempt has been made to relate the theoretical aspects with the skill covered in each
exercise to the extent possible. This correlation is maintained to help the trainees to develop the perceptional
capabilities for performing the skills.
The Trade Theory has to be taught and learnt along with the corresponding exercise contained in the manual
on trade practical. The indications about the corresponding practical exercises are given in every sheet of this
manual.
It will be preferable to teach/learn the trade theory connected to each exercise atleast one class before
performing the related skills in the shop floor. The trade theory is to be treated as an integrated part of each
exercise.
The material is not for the purpose of self learning and should be considered as supplementary to class room
instruction.
(vi)
CONTENTS
Exercise No. Title of the Exercise Page No.
Module 1: Drilling
2.1.61 Mark off and drill through holes 1
2.1.62 Drill on M.S Flat 4
2.1.63 File radius and profile to suit gauge 6
2.1.64 Sharpening of drills 10
2.1.65 Practice use of angular measuring instrument 16
2.1.66 Counter sink, counter bore and ream split fit (three piece fitting) 19
2.1.67 Drill through hole and blind holes 23
2.1.68 Form internal threads with taps to standard size (through holes
and blind holes) 26
2.1.69 Prepare studs and bolt 31
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2.1.70 Form external threads with dies to standard size 35
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2.1.71 Prepare nuts and match with bolts 37
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2.1.72 File and make step fit, angular fit, angle, surfaces (bevel gauge
accuracy 1 degree) 39
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2.1.73 Make simple open and sliding fits 42
2.1.74 Enlarge hole and increase internal dia 45

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2.1.75 File cylindrical surfaces 47

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2.1.76 Make open fitting of curved profiles 49

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2.1.77 Correction of drill location by binding previously drilled hole 52

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2.1.78 Make inside square fit 54
Module 2: Fitting assembly
2.2.79 Make sliding ‘T’ fit 56
2.2.80 File fit - combined, open angular and sliding sides 59
2.2.81 File internal angles 30 minutes accuracy open, angular fit 61
2.2.82 Make sliding fit with angles other than 90° 63
2.2.83 Scrap on flat surfaces, curved surfaces and parallel surfaces and test 67
2.2.84 Make and assemble, sliding flats, plain surfaces 72
2.2.85 Check for blue math of bearing surfaces - both flat and curved surfaces by
whitworth method 75
2.2.86 File and fit combined radius and angular surface (accuracy ± 0.5 mm)
angular and radius fit 77
(vii)
2.2.87 Locate accurate holes and make accurate hole for stud fit 80
2.2.88 Fasten mechanical components/sub-assemblies together using screws,

bolts and collars using hand tools 82
2.2.89 Make sliding fits assembly with parallel and angular mating surface 85
Module 3: Turning
2.3.90 Lathe operations 89
2.3.91 True job on four jaw chuck using knife tool 91
2.3.92 Face both the ends for holding between centres 94
2.3.93 Using roughing tool parallel turn ± 0.1 mm 96
2.3.94 Measure the diameter using outside caliper and steel rule 98
2.3.95 Holding job in three jaw chuck 101
2.3.96 Perform the facing, plain turn, step turn, parting, deburr, chamfer corner,
round the ends, and use form tools 103
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2.3.97 Shoulder turn : Square , filleted, beveled under cut shoulder, turning-filleted
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under cut, square beveled 108
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2.3.98 Sharpening of - single point tools 113

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2.3.99 Cut grooves - square, round ‘V’ groove 116
2.3.100 Make a mandrel - turn diameter to sizes 118

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2.3.101 Knurl the job 121

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2.3.102 Bore holes - spot face, pilot drill, enlarge hole using boring tool’s 124
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2.3.103 Make a bush step bore-cut recess, turn hole diameter to sizes 128
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2.3.104 Turn taper (internal and external) 133
2.3.105 Turn taper pins 138
2.3.106 Turn standard tapers to suit with gauge 140
2.3.107 Practice threading using taps, dies on lathe by hand 142
2.3.108 Make external ‘V’ thread 144
2.3.109 Prepare a nut and match with bolts 149
Module 4 : Basic Maintenance
2.4.110 Simple repair work - simple assembly of machine parts from blue prints 152
2.4.111 Rectify possible assembly faults during assembly 156

2.4.112 Perform the routine maintenance with check list 164
2.4.113 Monitor machine as per routine check list 167
(viii)
2.4.114 Read pressure gauge, temperature gauge, oil level 169
2.4.115 Set pressure in pneumatic system 170
2.4.116 Assemble simple fitting using dowel pins and cap screw assembly
using torque wrench 172
LEARNING / ASSESSABLE OUTCOME
On completion of this book you shall be able to
• Produce components by different operations and check accuracy
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using appropriate measuring instrument. [ Different Operations-
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Drilling, reaming, taping, dieing., Appropriate measuring
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instruments - Vernier, screw gauge, micrometer.]
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• Make different fit of components for assembling as per required

tolerance observing principle of interchargeability and check for
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functionality. [ Different fit-sliding, angular, step fit, ‘T’ fit, square fit
and profile fit., Required tolerance; ± 0.04 mm, angular tolerace: 30
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min]
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• Produce components involving different operations on lathe

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observing standard procedure and check for accuracy. [ Different

operations - Facing, plain turning, step turning, parting, chamfering,
shoulder turn, grooving, knurling, boring, taper turning, threading
(external ‘V’ only.]
• Plan & perform simple rapair, overhauling of different machines

and check for functionality. [ Different machines - Drill machine,
power saw, bench grinder and lathe.]
(ix)
SYLLABUS
Second Semester Duration: Six Month
Week Ref. Learning Professional Skills

Professional Knowledge
No. Outcome (Trade Practical)
(Trade Theory)
with Indicative hours
27 Produce componentsby 61 Mark off and drill through holes. Drill- material, types, (Taper shank,
different operations and (5 hrs.) straight shank) parts and sizes.
check accuracy using Drill angle-cutting angle for different
62 Drill on M.S. flat. (1 hrs.)
appropriate measuring materials, cutting speed feed.
instruments.[Different 63 File radius and profile to suit gauge R.P.M. for different materials. Drill
Operations-Drilling, (13 hrs.) holding devicesmaterial,
Reaming, Taping, Dieing; 64 Sharpening of Drills.(1 hrs.) construction and their uses.
Appropriate Measuring
Instrument – Vernier, Screw 65 Practice use of angular measuring
Gauge, Micrometer] instrument. (5 hrs.)
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28 -do- 66 Counter sink, counter bore and Counter sink, counter bore and spot
ish ream split fit (three piece fitting). facing-tools and nomenclature,
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(5 hrs.) Reamermaterial,
types (Hand and machine reamer),
67 Drill through hole and blind holes.
kinds, parts and their uses,
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(2 hrs.)
determining hole size (or reaming),
68 Form internal threads with taps to Reaming procedure.
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standard size (through holes and Screw threads: terminology, parts,

blind holes).(3 hrs.) types and their uses. Screw pitch
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69 Prepare studs and bolt.(15 hrs.) gauge: material parts and uses.
Taps British standard (B.S.W.,
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B.S.F., B.A. & B.S.P.) and metric /

BIS (course and fine) material, parts
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(shank body, flute, cutting edge).
29 -do- 70 Form external threads with dies to Tap wrench: material, parts, types
standard size. (10 hrs.) (solid &adjustable types) and their
uses removal of broken tap, studs
71 Prepare nuts and match with
(tap stud extractor). Dies: British
bolts.(15 hrs.)
standard, metric and BIS standard,
material, parts, types, Method of
using dies. Die stock: material,
parts and uses.
(x)
30 -do- 72 File and make Step fit, angular fit, Drill troubles: causes and remedy.
angle, surfaces (Bevel gauge Equality of lips, correct clearance, dead
accuracy 1 degree).(15 hrs.) centre, length of lips. Drill kinds:
Fraction, metric, letters and numbers,
73 Make simple open and sliding fits.
grinding of drill.
(10 hrs.)
31 -do- 74 Enlarge hole and increase internal Grinding wheel: Abrasive, grade
dia. (2 hrs.) structures, bond, specification, use,
mounting and dressing. Selection of
75 File cylindrical surfaces.(5 hrs.)
grinding wheels. Bench grinder parts
76 Make open fitting of curved and use. Radius/fillet gauge, feeler
profiles.(18 hrs.) gauge, hole gauge, and their uses, care
and maintenance.
32 -do- 77 Correction of drill location by binding Pig Iron: types of pig Iron, properties
previously drilled hole.(5 hrs.) and uses. Cast Iron: types, properties
and uses.
78 Make inside square fit. (20 hrs.)
33 Make different fit of 79 Make sliding „T. fit.(2 hrs.) Interchangeability: Necessity in Engg,
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components for field definition, BIS. Definition, types of
assembling as per limit, terminology of limits and fits-basic
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required tolerance size, actual size, deviation, high and low
observing principle
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of interchangeability standard systems of fits and limits.

and check for British standard system, BIS system
f u n c t i o n a l i t y.
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[Different Fit –
Sliding, Angular, Step
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fit, ‘T’ fit, Square fit

and Profile fit;
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Required tolerance:
±0.04 mm, angular
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tolerance: 30 min.]
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34 -do- 80 File fit- combined, open angular Method of expressing tolerance as per
and sliding sides. (10 hrs.) BIS Fits: Definition, types, description
of each with sketch. Vernier height
81 File internal angles 30minutes
gauge: material construction, parts,
accuracy open, angular fit.(15 hrs.)
graduations (English & Metric) uses,
care and maintenance.
35-36 -do- 82 Make sliding fit with angles other Wrought iron- : properties and uses.
than 90°.(25 hrs.) Steel: plain carbon steels, types,
properties and uses. Non-ferrous metals
(copper, aluminum, tin, lead, zinc)
properties and uses.
(xi)
37 -do- 83 Scrap on flat surfaces, curved surfaces Simple scraper- circular, flat, half
and parallel surfaces and test. (5 hrs.) round, triangular and hook scraper
and their uses. Blue matching of
84 Make & assemble, sliding flats, plain
scraped surfaces (flat and curved
surfaces. (15 hrs.)
bearing surfaces)
85 Check for blue math of bearing surfaces
- both flat and curved surfaces by with
worth method.(5hrs.)
38 -do- 86 File and fit combined radius and Vernier micrometer, material, parts,
angular surface (accuracy ± 0.5 mm), graduation, use, care and intenance.
angular and radius fit. (18 hrs.) Calibration of measuring
instruments. Introduction to
87 Locate accurate holes & make accurate
mechanical fasteners and its uses.
hole for stud fit.(2 hrs.)
Screw thread micrometer:
88 Fasten mechanical components / sub- Construction, graduation and use.
assemblies together using screws,
bolts and collars using hand tools.
(5 hrs.)
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39 -do- 89 Make sliding fits assembly with Dial test indicator, construction,
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parallel and angular mating surface. parts, material, graduation, Method
ish (± 0.04 mm) (25 hrs.) of use, care and maintenance.

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Digital dial indicator. Comparators-

measurement of quality in the
cylinder bores.
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40 Produce components 90 Lathe operations- Safely precautions to be observed

involving different while working on a lathe, Lathe
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91 True job on four jaw chuck using knife

operations on lathe specifications, and constructional
tool.(5 hrs.)
observing standard features. Lathe main parts
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procedure and check for 92 Face both the ends for holding between descriptions- bed, head stock,
accuracy. [Different centers. (9 hrs.) carriage, tail stock, feeding and
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Operations – facing, 93 Using roughing tool parallel turn ± thread cutting mechanisms. Holding
plain turning, step 0.1 mm. (10 hrs.) of job between centers, works with
turning, parting, catch plate, dog, simple description
chamfering, shoulder 94 Measure the diameter using outside of a facing and roughing tool and their
turn, grooving, knurling, caliper and steel rule.(1hrs.) applications.
boring, taper
turning, threading
(external ‘V’ only)]
41 -do- 95 Holding job in three jaw chuck.(2 hrs.) Lathe cutting tools- Nomenclature
ofsingle point & multipoint cutting
96 Perform the facing, plain turn, step turn,
tools, Tool selection based on
parting, deburr, chamfercorner, round
different requirements and necessity
the ends, and use form tools. (11 hrs.)
of correct grinding, solid and tipped,
throw away
(xii)
97 Shoulder turn: square, filleted, type tools, cutting speed and feed and
beveled undercut shoulder, turning- comparison for H.S.S., carbide tools.
filleted under cut, square beveled. Use of coolants and lubricants.
(11 hrs.)
98 Sharpening of -Single point Tools.
(1 hrs.)
42 -do- 99 Cut grooves- square, round,V. Chucks and chucking the independent
groove. (10 hrs.) four-jaw chuck. Reversible features of
jaws, the back plate, Method of clearing
100 Make a mandrel-turn diameter to
the thread of the chuck-mounting and
sizes. (5 hrs.)
dismounting, chucks, chucking true,
101 Knurl the job.(1 hrs.) face plate, drilling - method of holding
102 Bore holes –spot face, pilot drill, drills in the tail stock, Boring tools and
enlarge hole using boring tools. enlargement of holes.
(9 hrs.)
43 -do- 103 Make a bush step bore-cut recess, General turning operations- parallel or
turn hole diameter to sizes.(5 hrs.) straight, turning. Stepped turning,
grooving, and shape of tools for the
104 Turn taper (internal and external).
above operations. Appropriate method of
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(10 hrs.)
holding the tool on tool post or tool rest,
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105 Turn taper pins. (5 hrs.) Knurling: - tools description, grade,
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106 Turn standard tapers to suit with uses, speed and feed, coolant for
knurling, speed, feed calculation.
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gauge.(5 hrs.)
Taper – definition, use and method of
expressing tapers. Standard tapers-
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taper, calculations morse taper.

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44 -do- 107 Practice threading using taps, dies Screw thread definition – uses and
on lathe by hand. (2 hrs.) application. Square, worm, buttress,
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acme ( non standard-screw threads),

108 Make external „V. thread.(8 hrs.)
Principle of cutting screw thread in
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109 Prepare a nut and match with the centre lathe –principle of chasing the
bolt.(15 hrs.) screw thread – use of centre
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gauge,setting tool for cutting internal and

external threads, use of screw pitch
gauge for checking the screw thread.
45-46 Plan & perform 110 Simple repair work: Simple assembly Maintenance
simple repair, of machine parts from blue prints. -Total productive maintenance -
overhauling of (15 hrs.) Autonomous maintenance -Routine
different machines maintenance -Maintenance schedule
111 Rectify possible assembly faults during
and check for -Retrieval of data from machine
assembly.(19 hrs.)
f u n c t i o n a l i t y. manuals Preventive maintenance-
[Different Machines 112 Perform the routine maintenance with objective and function of Preventive
– Drill Machine, check list (10 hrs.) maintenance, section inspection.
Power Saw, Bench 113 Monitor machine as per routine Visual and detailed, lubrication survey,
Grinder and Lathe] checklist (3 hrs.) system of symbol and colour coding.
Revision, simple estimation of
114 Read pressure gauge, temperature materials, use of handbooks and
gauge, oil level (1 hrs.) reference table. Possible causes for
115 Set pressure in pneumatic system assembly failures and remedies.
(2 hrs.)
(xiii)
47 -do- 116 Assemble simple fitting using Assembling techniques such as
dowel pins and tap screw aligning, bending, fixing, mechanical
assembly using torque wrench. jointing, threaded jointing, sealing, and
(25 hrs.) torquing.Dowel pins: material,
construction, types, accuracy and uses.
48-49 In-plant training / Project work

1 Pipe Fixture
2 Adjustable Clamp
3 Hermaphrodite/ Inside Caliper
4 Chuck Key
50-51 Revision
52 Examination
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(xiv)
Production & Manufacturing Exercise 2.1.61
Fitter - Drilling
Mark off and drill through holes

Objectives: At the end of this exercise you shall be able to
• mark drill holes as per drawing
• drill through holes using pedestal drilling machine.
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1
Job Sequence
• Check the raw material for its size. • Fix Ø 6 mm drill and drill pilot holes in all centre drilled
holes.
• File and finish to size 85 x 72 x 9 mm maintaining
parallelism and perpendicularity. • Similarly fix Ø 8 mm, Ø 10 mm, Ø 12 mm, and 16mm
drill in drilling machine and drill holes as per drawing.
• Mark drill holes as per drawing.
• Finish file and de - burr in all the surfaces of the job.
• Punch on drill hole centres using centre punch 90°
• Check the size with vernier caliper.
• Make centre drill in all drill hole centres.
• Apply a thin coat of oil and preserve it for evaluation.
Skill Sequence
Drilling through holes

Punch the centre of the hole to be drilled by a centre punch. Ensure that the drill do not penetrate into the vice.
Set the job in the machine vice securely by using two Fix securely the drill deep into the drill chuck. (Fig 2)
parallel bars to clear the drill (Fig 1)
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Fix the drill chuck into the spindle of the drilling machine .
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Fix centre drill and drill in all hole centres. Since the web of large diameter drills are thicker, the dead
Fix Ø 6mm dia drill in the drill chuck for pilot hole. centres of those drills do not sit in the centre punch marks.
This can result in the shifting of the hole location. Thick
Select the spindle speed by shifting the belt in the dead centres can not penetrate into the material easily and
appropriate cone pulleys. will impose severe strain on the drill.
Drill all the holes first by Ø 6mm drill. This will serve as a These problems can be overcome by drilling pilot holes
pilot hole for Ø 8mm 10 mm, 12 mm and 16 mm dia drills. initially. (Fig 3)
Similarly, drill Ø 8mm hole, then drill 10 mm, 12 mm holes.
Remove the drill and drill chuck.
Fix Ø 16 mm taper shank drill in the drilling machine
spindle.
Change the spindle speed to suit Ø 16 mm drill and drill the
hole.
Caution: Do not remove chips with your bare
hands - use brush.
Do not try to change the belt while the machine
is running.
2 Production & Manufacturing: Fitter (NSQF Level - 5) Exercise 2.1.61

Use drift to remove the drill chuck and taper shank drill
from drilling machine spindle (Fig 4)
Set the spindle speed according to the diameter of drills.
For smaller diameter drill keep the spindle speed in higher
R.P.M and for larger diameter of drill keep the spindle speed
in lower R.P.M.
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Production & Manufacturing: Fitter (NSQF Level - 5) Exercise 2.1.61 3

Fitter - Drilling
Drill on M.S Flat

• mark drill hole centres
• hold the job in drilling machine table
• set the spindle speed according to the diameter of drill
• drill through holes as per drawing
• finish and de-burr.
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4
Job Sequence
• Check the raw material for its size. • Fix Ø 5 mm drill in drilling machine spindle through
drill chuck.
• File surface to flatness.
• Set suitable spindle speed according to the size of
• File right angle to squareness. drill.
• File metal to size 63 x 63 x 9 mm maintaining parallelism • Drill Ø 5 mm through hole in job.
and perpendicularity
• Remove Ø 5 mm drill from drill chuck.
• Check the flatness and squareness with try square
and size with vernier caliper. • Similarly, fix Ø 7, Ø 9 and Ø 11mm drill in drill chuck
and drill through holes as per drawing.
• Apply marking media, mark dimension lines as per
drawing and punch the witness marks using dot punch. • Check the size with vernier caliper.
• Punch on the drill holes centre using centre punch. • Finish and de - burr all the corners of the job.
• Hold the job in drilling machine table for drilling. • Apply a little oil on the job and preserve it for evaluation.
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Fitter - Drilling
File radius and profile to suit gauge

• file and mark as per job drawing
• file internal and external radius
• check the radius using radius gauge.
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6
Job Sequence
• Check the raw material for its size.
• File metal to overall size 60x40x10 mm maintaining
parallelism and perpendicularity and check flatness and
squareness.
• Mark off all dimensions as per drawing.
• Mark the radius using divider and punch the identification
marks.
• Drill Ø 4mm to form internal radius 2 mm.
• Chain drill holes for parting off excess material from
inside. (Hold the job rigidly, use a coolant and set
correct RPM for drilling.)
• Hacksaw along the inner edges.
• Separate the excess material from inside using a
webchisel and Ball pein hammer.
• File inside slot as per drawing.
• Hacksaw, file and finish angle and outside surfaces.
• File and finish external radius and check with the radius
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gauge. • Apply a little oil on the job and preserve it for evaluation.
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• File and smooth finish all sides maintaining While chain drilling ensure 1 mm space
±0.04 mm.
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Skill Sequence
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Parting off by chain drilling

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Objective: This shall help you to

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• part off metal by chain drilling.

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The shape of certain job features is such that metals are to

be cut in places which are inaccessible for hacksawing by
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hand.
While there are many methods for doing this, the most
common method adopted in bench fitting is to chain drill in
such places, and hacksaw other sides, if possible.
After chain drilling and hacksawing the other sides, a chisel
is used to part off the metal A. (Fig 1)
If the workpiece is not thick enough, parting with an
ordinary flat chisel will cause distortion to the workpiece.
The best method is to use a PUNCHING CHISEL or WEB
CHISEL to remove the metal web between the drilled holes.
The web chisel (punching chisel) has a double cutting
edge, and this reduces the possibility of distortion to
workpieces.
While cutting the web, the chisel is kept at an angle.
(Fig 2)
Remove only thin chips of equal thickness.
Thick workpieces need cutting with a web chisel from both
sides.

If the web thickness is kept too small, a slight inaccuracy
in drilling will draw the drill to the hole already drilled and
While marking for chain drilling, place the location of drill cause damage to the drill.
centres in such a way that the web is not too thick. (Fig 3)
For easier parting off, select suitable hole size to permit the
About 1 mm thick web is convenient for drilling and chisel to enter and leave minimum material for filing.
separating with a chisel.
Cutting with a web chisel will produce sharp
cutting edges. Handle the workpieces carefully.
Filing radius (external)

• file external radius.
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Filing radius is entirely a different technique, and needs
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considerable skill for filing accurately with a good finish.
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In this type of filing, the file has to be held perfectly
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horizontal widthwise, and at the same time a rocking

motion given lengthwise. The surface filed should not have
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any flat surface and should have a uniform curve. Radius

filing of external surfaces is carried out in different steps.
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Rough filing of corners

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The corners are filed and brought closely to line using a

bastard file. (Fig 1)
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Rounding of corners
The flat surfaces are rounded and brought near about to
finishing size, using a second cut file. In this, the file is
moved forward across the curve with a turning motion. While filing make sure
(Fig 2)
- to check the radius frequently with a radius gauge
Check periodically with a radius gauge.
- to use the broad surface to the job as datum for checking
Final finishing of radius the size
For finishing steps, a smooth file is used. The file is given - not to give excessive pressure while filing radius as the
a see-saw motion along the curved line until the required file is likely to slip.
radius is formed. (Fig 3)

Checking the radius
• check the radius with a radius gauge.
Before checking with a radius gauge ensure the radius

gauge is perfectly clean. Remove burrs, if any, from the
workpiece. Check and make sure the profile of the gauge
is not damaged.
The radius gauge should be held perpendicular to the
radius to be checked. (Fig 1 and 2)
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The right radius is the one that matches correctly with the
gauge. (Fig 5)
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Observe the contact surfaces for any light passing through.

Check against the background of light. The gauge should
be moved along the filed length of the radius for checking.
(Fig 3 and 4)
File and adjust the radius gradually according to the radius
gauge. After using the radius gauges, wipe them clean
with a clean cloth and apply a light film of oil
before storing.

Fitter - Drilling
Sharpening of drills
• dress the grinding wheel
• sharpen the drill in pedestal grinder
• check the drill angle using drill gauge.
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10
Job Sequence
• Hold the blunt twist drill properly in both hands. Swing the shank of the drill slightly downwards
• Place the drill on tool rest. while grinding.
• Touch the cutting edge of a twist drill in grinding wheel While sharpenning drill, the cutting edges
face maintaining 31°angle from grinding stone. length and angles should be equal.
• Twist the drill slightly on wheel face and grind one cutting • Check the cutting angle and cutting edge length in drill
edge to the required angle to get 59°. grinding gauge.
• Similarly, grind the other cutting edge to the required • Switch off the grinding machine and clean properly.
angle to get 59° maintaining the cutting edges length Wear safety goggles while sharpening twist
equal. drills.
Skill Sequence
Off - Hand grinding with bench and pedestal grinders

Objectives: This shall help you to
• identify the grinding machine and parts.
Off - hand grinding is the operation of removing material Pedestal grinders
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which does not require great accuracy in size or shape.
Pedestal grinders are mounted on a base (pedestal), which
This is carried out by pressing the workpiece by hand
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against a grinding wheel.
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Off - hand grinding is performed for rough grinding of jobs
These grinders consist of an electric motor and two
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spindles for mounting grinding wheels. On one spindle a

and resharpening wheel.
coarse - grained wheel is fitted, and on the other, a fine
scribers grained wheel. For safety, while working, wheel guards
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punches are provided. (Fig 1 and 2)

chisels
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A coolant container is provided for frequent cooling of the

twist drills
work. (Fig 2)
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single point cutting tools etc.

Adjustable work - rests are provided for both wheels to
off - hand grinding is performed with a bench or pedestal support the work while grinding. These work - rests must
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grinder. (Fig 1 and 2) be set very close to the wheels.

Extra eye - shields are also provided for the protection of
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the eyes. (Fig 2)
Bench grinders
Bench grinders are fitted to a bench or table, and are useful
for light duty work.

Re-sharpening a twist drill
Objective : This shall help you to
• re-sharpen a twist drill.
A twist drill can be successfully sharpened on a bench or

pedestal grinder by adopting the following preocedure.
Check that the surface of each wheel is running true and
that the wheels are dressed clean.
Ensure that the tool-rest are adjusted correctly
and tightened.
Wear safety goggles.
Stand in a comfortable position in front of the machine.
Hold the drill at about one quarter of its length from the
point, between the thumb and the first finger of the right
hand. (Fig 1)
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the shank, swings down, the cutting edge comes slightly

upwards and away from the wheel face. (Fig 5)
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Keep both elbows against the side.

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Position yourself in such a way that the drill makes an

angle of 59° to 60° to the wheel face. (Fig 2)
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Apply a slight foward motion to your hands.

This will bring the flank of the point against the wheel to
produce a lip clearance.
Coordinate the three movements of swinging
down, twisting clockwise and forward
movement. These movements should not be
heavy movements. If they are performed
correctly, they will produce a cutting edge that
has the correct lip clearance and cutting angle.
Practice these movements against a stationary wheel,
Hold the drill level. Twist it until one cutting edge is horizontal using a new or correctly sharpened drill.
and parallel to the wheel face. (Fig 3) Notice how only a small movement is required to produce
Swing the shank of the drill slightly downwards and to the the required clearance.
left with the left hand. The right hand is on the tool-rest.
Also note that, if the drill is twisted too far, the other cutting
(Fig 4)
edge will swing down to contact the wheel face.

Proceed now to sharpen one edge, removing as little metal Hold the drill shank again in the left hand with the elbows
as possible. against the side. The drill will locate back against the
wheel face in the same position and at the same angle as
Procedure to obtain equal angles
before.
Move the drill back, clear of the wheel face.
Points to be considered when sharpening drills
Turn the drill over without moving the position. This presents
Grind as little as possible from the drill. Remove only
the second edge to the wheel face at the same angle as
enough to sharpen the cutting edges.
the first cutting edge.
Rough down the drill point with a coarse grit wheel when
Proceed to sharpen the second cutting edge, using the
the edges are badly chipped.(Fig 7)
same amount of drill movement as before. When these
actions are carried but carefully, the drill will be sharpened
with equal cutting angles. The lip clearance will be correct
and equal.
Use a drill angle gauge to check that the cutting angle is
correct (118° for mild steel), the cutting edges are of equal
length and the lip clearances are equal and correct (about
12°). (Fig 6)
Never re-sharpen a cracked or split drill.

Avoid overheating the drill.
Apply light pressure against the wheel face. Lift the edge
clear of the wheel face frequently. This allows the air stream
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produced by the wheel to cool the drill point.(Fig 8)
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Lift the drill off the wheel face. Retain the grip on the drill Cooling a drill rapidly by quenching in cold
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with the right hand. water may cause cracking of the cutting edge.
Make such inspection or checks as are necessary. Move Re-sharpening of very small drills requires great skill. They
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the right hand back on-the tool-rest in the same position require proportionally less movement to produce the
as before. cutting angles.
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Testing a re-sharpened twist drill for its performance

• test the drill that has been re-sharpened by drilling a through hole.
Set the spindle revolution of the drilling machine to.give a • Require only moderate pressure to feed it into the work.
cutting speed of 25 to 30 meters per minute. A drill that
When the hole has been drilled through, take the drill out
has been re-sharpened correctly will:
of the machine and try it by inserting into the hole.
• Produce two evenly curled chips from its cutting edges
If the drill fits without any play it means that (Fig 2):
(Fig 1)

• the cutting edges and angles are equal
• the drill has produced a hole of the correct size.
Any looseness of the drill in the hole means (Fig 3):
• the cutting edges are of uneven length
• the drill has produced an oversized hole.
A drill that has been ground with uneven or too great a lip
• tend to chatter during starting
clearance will
• produce an out-of-round hole.
Safe working on off - hand grinders

• work safely on an off - hand grinder.
How to work on an off - hand grinder?
While working on off - hand grinder, it is important to

observe the following safety measures.
Before starting
Make sure the grinding wheel guards are in place.
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Wear safety goggles while grinding. (Fig 1)
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Stand on one side of the machine while starting.

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Adjust the tool - rest as close to the wheel as possible.

Caution: If any abnormal sound is noticed, stop
The maximum recommended gap is 2 mm. This will help
the machine. Cracked or improperly balanced
to prevent the work from being caught between the tool rest
wheels are dangerous.
and the wheel. (Fig 2)
Do not work on grinding wheels which are loaded or glazed.
Dress and true wheels whenever necessary. (Fig 3)
Dressing a grinding wheel

• dress a grinding wheel.
When grinding wheels are loaded or glazed, they are Make the dresser come in contact with the wheel by
rectified by dressing. slowly lifting the handle.
Dressing of pedestal grinder wheels is carried out by a As the dresser star - wheel starts rotating, there can be a
star - wheel dresser. jerk. This can be overcome by pressure exerted on the
work - rest.
For correct setting of the star - wheel dresser, the work -
rest should be adjusted so that the dresser pivots get Press the dresser firmly against the grinding wheel and
positioned between the wheel and the work - rest. (Fig 1) move it across the face.

Read just the work - rest as close to the grinding wheel
as possible. (Fig 2)
Do not run off the edge of the wheel while moving across.
Do not release the downward pressure on the work - rest
while lifting the handle. Wear safety goggles and gloves while dressing
a grinding wheel. Stand on one side of the
Do not exert excessive pressure; it can crack the grinding
grinder while starting. Hold the dresser firmly
wheel.
while dressing. Do not put excessive pressure
Move the dresser across the face of the grinding wheel on the grinding wheels.
until all the metal particles are removed, and the face is
straight.
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Fitter - Drilling
Practice use of angular measuring instrument

• measure the different acute angle and obtuse angle of components using vernier bevel protractor.
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Job Sequence
• Measure the different angle using vernier bevel
Note: Instructor shall arrange the different
protractor.
angular components for praticing with angular
measuring instruments. • Enter the angle in Table 1.
TABLE - 1
Part Number Angle measured

1
2
3
4
5
6
7
8
9
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Get it checked by your instructor.
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Skill Sequence
Vernier bevel protractor

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• identify the parts of a universal bevel protractor.

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The vernier bevel protractor is a precision instrument meant

for measuring angles precisely to an accuracy of 5 minutes.
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(5’)
Parts of a vernier bevel protractor
The following are the parts of a vernier bevel protractor,

(Fig 1)
Stock, Disc, Dial, Blade Locking screws.

Reading of vernier bevel protractor
• read vernier bevel protractor for acute angle setting
• read vernier bevel protractor for obtuse angle setting.
For reading acute angle set up (Fig 1) If you read the main scale in an anticlockwise direction,
read the vernier scale also in an anticlockwise direction
from zero.
If you read the main scale in a clockwise direction, read the
vernier scale also in a clockwise direction from zero.
For obtuse angle set up (Fig 3)
The vernier scale reading is taken on the left side as
indicated by the arrow. (Fig 4) The reading value is
subtracted from 180° to get the obtuse angle value.
Reading 22°30’
Measurement
180° - 22°30’ = 157°30’
First read the number of whole degrees between zero of the
main scale and zero of the vernier scale. (Fig 2)
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Note the line on the vernier scale that exactly coincides

with any one of the main scale divisions and determine its
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value in minutes.
To take the vernier scale reading, multiply the coinciding
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divisions with the least count.

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Example: 10 x 5’ = 50’
Total up both the readings to get the measurements = 41°
50’

Fitter - Drilling
Counter sink, counter bore and ream split fit (three piece fitting)
• mark the lines as per job drawing
• drill, counter sink, counter bore and ream the holes as per drawing
• cut and remove excess metal in part 1 and 2
• file and finish to size and shape, make split fit as per drawing.
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Job Sequence
• Check the raw material for its size. • Ream in Ø 9.8 mm two drilled holes using Ø 10 mm
hand reamer with wrench.
• File and finish to over all size of part 1 and 2 to
60 x 40 x 9 mm, part 3 to the size of 29 x 29 x 9 mm • Hold part 1 in bench vice.
maintaining parallelism and perpendicularity.
• Cut and remove excess metal by hacksawing.
• Mark the hole centres and punch in part1 and 2 as per
• File to size and shape as per job drawing.
job drawing.
• Similarly, repeat the above process in part 2 and
• Fix the job in drilling machine table with suitable
complete the job.
clamps.
PART - 3
• Fix centre drill in drilling machine spindle through drill
chuck and drill centre drilling in all drill holes centres. • Mark the dimension lines as per drawing and punch
witness marks in part 3.
• Fix Ø 6 mm drill in drill chuck and drill through holes
as per drawing in all centre in drilled holes. • Cut and remove excess metal by sawing and file to
size and shape as per drawing.
• Similarly, fix Ø 9.8 mm drill in drill chuck and drill
through holes in ream hole locations. • Match part 1, 2 ,3 and make three pieces as split fit.
• Fix counter sink tool in drilling machine and counter • De - burr in all the surfaces and corners of the jobs.
sink two holes to the required depth.
• Apply oil and preserve it for evaluation.
• Similarly, fix counter bore tool in drilling machine and
counter bore two holes to the required depth.
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Skill Sequence
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Counter sink
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• countersink holes of different sizes.
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Selection of countersinks
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Select the countersink tool according to the angle of the

taper head of the screw. Use the table for countersink
holes.
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Fix the job in the machine vice (if necessary, use parallel
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blocks) and set it square.

Align the machine spindle with the drilled hole to be
countersunk. (Fig 1)
Substitute the recommended speed of the countersink.

(V = 1/3rd of the cutting speed for drilling)
Countersink hole to a depth equal to the head length of the
screwhead. (Fig 3)
Remove the drill and fix the countersink tool on the machine
without disturbing the alignment. (Fig 2) Check the countersink hole with a suitable countersink
head screw for proper seating. (Fig 4)
Set the spindle speed of the drilling machine RPM. Use the
formula

Counterboring
• counterbore holes of different sizes concentric to the drilled holes.
Selection of counterbore sizes

πxdxn
V=
B.I.S. recommends different sizes of counterbores based 1000
on the sizes of the clearance holes.
(Consider the value of `V` as 1/3rd of the cuting speed for
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Select the counterbore according to the screw size. drilling)
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Fix the job in the machine vice, square to the axis of the Counterbore the hole to a depth slightly more than the
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machine spindle. Use parallel blocks. (Fig 1) thickness of the screwhead (Figs 3 & 4)
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Set the location of the drilled hole position using the correct
diameter drills.
Align the spindle axis with the drilled hole. For accurate
work, drill and counterbore in one setting.
Mount and fix the counterbore tool on the drilling machine
spindle. (Fig 2)
Use the depth stop arrangement for controlling the depth of

the counterbore hole.
Check the depth of the counterbored hole. (Use the correct
screw for checking the depth and seating).
Set the spindle speed of the driling machine to the nearest

calculated RPM. Use the formula

Reaming drilled holes using hand reamers
• ream through holes within limits and check reamed holes with cylindrical pins.
Determining the drill size for reaming

Use the formula,
drill diameter = reamed hole size. (undersize + oversize)
Refer to the table for the recommended undersizes in
Related Theory on DRILL SIZES FOR REAMING.
Hand reaming
Drill holes for reaming as per the sizes determined.
Place the work on parallels while setting on the
machine vice. (Fig 1)
Do not turn in the reverse direction it will

scratch the reamed hole. (Fig 4)
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Chamfer the hole ends slightly. This removes burrs, and

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will also help to align the reamer vertically (Fig 2). Fix the
work in the bench vice. Use vice clamps to protect the
finished surfaces. Ensure that the job is horizontal.
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Ream the hole through. Ensure that the taper lead length
of the reamer comes out well and clear from the bottom of
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the work. Do not allow the end of the reamer to strike on

the vice.
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Remove the reamer with an upward pull until the reamer is

clear of the hole. (Fig 5)
Fix the tap wrench on the square end and place the reamer
vertically in the hole. Check the alignment with a try
square. Make corrections, if necessary.Turn the tap
wrench in a clockwise direction applying a slight downward
pressure at the same time (Fig 3). Apply pressure evenly
at both ends of the tap wrench.
Apply cutting fluid.
Turn the tap wrench steadily and slowly, maintaining the
downward pressure.
Remove the burrs from the bottom of the reamed hole.

Clean the hole. Check the accuracy with the cylindrical
pins supplied.

Fitter - Drilling
Drill through hole and blind holes

• mark drill hole centres using vernier height gauge
• set the correct spindle speed in drilling machine
• drill through hole as per drawing
• set the depth bar to drill blind hole
• drill blind hole to the required depth size.
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Job Sequence
• Check the raw material size. • Make centre drill in drill holes centres.
• File and finish the metal to size 60 x 60 x 19 mm • Fix Ø 6mm drill in drilling machine spindle through drill
maintaining parallelism and perpendicularity. chuck and drill pilot holes for both through and blind
holes.
• Check the flatness and squareness with try square
and size with vernier caliper. • Fix Ø 8.5 mm drill and drill through hole as per drawing.
• Apply marking media and mark drill holes centres using • Fix Ø 10.5 mm drill and drill blind hole to the required
vernier height gauge as per drawing. depth of 14 mm.
• Punch on drill holes centres using centre punch 90° • File and de - burr in all the surfaces of the job.
• Hold the job in drilling machine table. • Apply a thin coat of oil and preserve it for evaluation.
Skill sequence
Drilling blind holes

• drill blind holes to the required depth using the depth stops.
Method of controlling depth of blind holes Setting for drilling blind holes
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While drilling blind holes, it is necessary to control the For blind hole - depth setting, first the work is held on the
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feed of the drill. Most machines are provided with a depth machine and the hole is located correctly.
stop arrangement by which the downward movement of
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The drill is started, and it drills until the full diameter is
the spindle can be controlled. (Fig 1)
formed. Note down the initial reading at this point. (Fig 2)
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Add the initial reading to the depth of the blind hole to be

drilled.
Initial reading + Depth of hole = Setting.
Adust the stop next to the required setting, using the scale.
Tighten the lock nut to prevent the setting from being
disturbed.
Start the machine and feed the drill. When the stop nut
reaches the arm, the blind hole is drilled to the required
depth. (Fig 3)
Most depth stop arrangements will have graduations by While drilling, release the drill frequently from
which the advancement of the spindle can be observed. the hole for the chips to be flushed out by the
Generally the blind hole depth tolerances are given up to cutting fluid.
0.5 mm accuracy.

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Fitter - Drilling
Form internal threads with taps to standard size (through holes and blind
holes)
• chamfer the holes for tapping
• fix the job in bench vice
• select the tap set
• cut internal threads in through and blind holes using hand tap and tap wrench.
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26
Job Sequence
Cut internal thread in through hole • Screw a matching nut on the first tap to the required
distance for 14 mm to act as a depth stop.
• Use Ex.No 2.1.67 for this excercise.
• Cut internal thread in blind hole to the required depth
• Fix the job in bench vice. 14 mm.
• Fix M 10 first tap in tap wrench and cut internal thread • Remove the metal chips, if any from the threaded blind
in through hole. hole.
• Similarly, fix M 10 second tap and third tap in tap wrench • Similarly, fix M 12 second tap and third tap in tap wrench
one by one and cut the internal thread to form full thread. one by one and cut the thread to form full thread.
• Repeat the above process to cut internal thread in other • Clean the threaded hole without burrs.
drilled through hole.
• Repeat the above process to cut internal thread in other
Cut internal thread in blind hole drilled blind hole.
• Remove metal chips if any from the blind hole by turning • Check the threaded hole using the M10, and M12
it upside down and slightly tapping it on a wooden matching bolts by screwing.
surface.
• Apply thin coat of oil and pressure it for evaluation.
• Fix the M 12 first tap in tap wrench.
Use cutting fluid while cutting the thread.
Internal threading of through holes using hand taps
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• determine the tap drill sizes for internal threading
• cut internal threads using hand taps.
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Determining the tap drill size

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For cutting internal threads, it is necessary to determine

the size of the hole (tap drill size). This can be calculated
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using the formula or can be chosen from the table of the tap
drill sizes.
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Procedure
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Drill the hole to the required tap drill size.

Do not forget to give the chamfer required for
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aligning and starting the tap. (Fig 1)

Hold the work firmly and horizontally in the vice. The top
surface should be slightly above the level of the vice jaws.
This will help in using a try square without any obstruction
while aligning the tap (Fig 2).
Use soft jaws while holding the finished surface
on the vice.
Fix the first tap (taper tap) in the wrench.
Too small a wrench will need a greater force to
turn tap. Very large and heavy tap wrenches
will not give the feel required to turn the tap
slowly as it cuts.
Position the tap in the chamfered hole vertically by ensuring
the wrench in a horizontal plane.
Exert steady downward pressure and turn the tap wrench
slowly in a clockwise direction to start the thread. Hold the When you are sure of starting of the thread, remove the tap
tap wrench close to the centre. (Fig 3) wrench without disturbing the tap alignment.
Check and make sure the tap is vertical. Use a small try
square for help. (Fig 4)

Place the try square in two positions, 90° to each other.
(Fig 5)
Make corrections, if necessary. This is done by exerting

slightly more pressure on the opposite side of the tap
inclination. (Fig 6)
Never apply side pressure without giving a
turning motion to the tap.
Check the tap alignment again with a try square.
Fit the tap wrench, and tighten without disturbing the tap
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alignment.
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Make one or two turns and check the alignment.
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turns. Afterwards this cannot be done for the threads will

break.
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After the tap is positioned vertically, turn the wrench lightly

by holding the ends of the wrench handles without exerting
any downward pressure. (Fig 7)
While turning the wrench, the movement should be well
balanced. Any extra pressure on one side will spoil the tap
alignment and can also cause breakage of the tap.

Continue cutting the thread. Turn backwards frequently,
about quarter turn, to break the chip. (Fig 8) Stop and turn
backwards also when some obstruction to movement is
felt.
Use a cutting fluid while cutting the thread.
Cut the thread until the tap is fully inside the hole being
threaded.
Finish and clean up using intermediate and plug tap. The
intermediate and plug tap will not cut any thread if the tap
has entered the hole fully.
Remove the chips from the work with a brush.
Check the threaded hole with a matching screw.
Clean the tap with a brush, and place it back on the stand
(Fig 9)
Internal threading blind holes using hand taps

• cut internal threads using hand taps.
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Drilling a blind hole
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Determine the tapping drill size using the table for tapping
drill sizes.
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Drill a blind hole using the depth stop arrangement. The

depth of the tapping hole should be slightly more than the
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depth of the required thread. (Fig 1)

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Procedure for threading

Remove metal chips, if any, from the blind hole by turning
it upside down and slightly tapping it on a wooden surface.
Do not clear the chips by blowing as it can
cause injury to your eyes.
Screw a matching nut on the first tap to act as a depth
stop. (Fig 2) Finish tapping the hole with intermediate and bottoming
tap. Set the nut to control the depth of the thread. (Fig 4)
Thread the blind hole until the nut touches the plate surface.
Remove the chips from the hole frequently, using a flattened
and bend wire. (Fig 3)

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Fitter - Drilling
Prepare studs and bolt

• file blank size to cut external thread for studs and bolts
• chamfer in both ends of studs and bolts
• mark the length required to cut external thread in studs and bolt
• cut external thread using die and die stock in studs and bolt
• check the external thread using screw pitch gauge and matching nuts.
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Job Sequence
TASK 1: Prepare stud
• Check the raw material size. • Apply pressure on the die stock evenly and turn in a
clock wise direction to advance the die in stud blank
• File the round rod ends to flatness and squareness and reverse the die for a short distance to break the
maintaining size Ø 10 mm x 70 mm length. chips.
• File round rod cylindrical profile to Ø 9.9 mm blank • Following the above processes, cut the external thread
size to cut external thread as per drawing. upto the required length as per drawing.
• File chamfer in both ends of the round rod to 2 mm x • Clean the thread and check with suitable screw pitch
45° gauge and matching nut.
• Apply marking media on cylindrical surface of the job • If the nut is not fitted with the external thread, increase
and mark the required length and punch witness marks the depth of cut gradually by adjusting the split die
to cut external thread as per drawing. stock outer screws and deepen the cut of thread to
• Hold the cylindrical rod in bench vice to 90° with correct pitch of thread and check with matching nut
aluminium vice clamps and check the 90° with try and screw pitch gauge.
square. • Similarly, repeat the thread cutting process in other
• Set M10 circular split die in die stock. end of cylindrical round rod to the required length and
check with suitable screw pitch gauge and match with
• Place the split die on the cylindrical round rod one end suitable nut.
and cut external thread by rotating in clock wise and
anti-clockwise direction to cut external thread. • Clean the thread without burrs and apply little oil and
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preserve it for evaluation.
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TASK 2: Prepare bolt
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• File the hexagon rod ends to flatness and squareness
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maintaining size Ø 10 mm x 40 mm length

• Apply marking media and mark dimensions to prepare
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hexagonal head bolt blank as per job drawing.

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• Punch witness marks using dot punch 60°. (Fig 1)

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• Cut and remove excess metal by sawing.

• File hexagonal rod cylindrical blank size to
Ø 9.9 mm x 18 mm length to cut external thread.
• Check the die to 90°, to the hexagonal head bolt blank
(Fig 2)
while cutting external thread.
• File chamfer in both ends of hexagon 2 mm x 45°
• Apply pressure on the die stock evenly and cut external
• Hold the Hexagonal head bolt in bench vice to 90°along thread as shown in job drawing.
with aluminium vice clamps.
• Check the thread with screw pitch gauge and matching
• Set M10 split die in the die stock. nut.
• Place the split die on the hexagonal head bolt round • Clean the thread and apply oil and preserve it for
blank end with die stock and turn in clock wise direction evaluation.
and anti-clockwise direction to cut external thread.
Use a cutting lubricant while cutting thread
(Fig 3)
Skill Sequence
External threading using dies

• Cut external threads using dies.
Check blank size.

Blank size = Thread size - 0.1 x pitch of thread
PROCEDURE
Fix the die in the diestock and place the leading side of
the die opposite to the step of the diestock. (Fig 1 & 2)
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Use vice clamp for ensuring a good grip in the

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vice.
Project the blank above the vice - just the
required thread length only.
Place the leading side of the die on the chamfer of the
work. (Fig 3)
Make sure that the die is fully open by tightening the centre
screw of the diestock. (Fig 4)
Start the die, square to the bolt centre line. (Fig 5)

Apply pressure on the diestock evenly and turn in a
clockwise direction to advance the die on the bolt blank.
(Fig 5)
Cut slowly and reverse the die for a short distance in order
to break the chips.
Use a cutting lubricant
Increase the depth of the cut gradually by adjusting the
outer screws.
Check the thread with a matching nut.
Repeat the cutting until the nut matches.
Too much depth of cut at one time will spoil
the threads. It can also spoil the die.
Clean the die frequently to prevent the chips
from clogging and spoiling the thread.
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Fitter - Drilling
Form external threads with dies to standard size

• file blank size in round rod to cut external thread
• cut M14 external thread using split die and die stock to the required length
• check the thread with screw pitch gauge and matching nut.
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35
Job Sequence
• Check the raw material for its size. • Cut external thread slowly and reverse the die for short
distance in order to break the chips.
• File blank size to Ø 13.9 mm x 40 mm length as per
drawing. • Increase depth of cut gradually by adjusting the screws
and cut the thread to correct pitch of the thread.
• File chamfer in both ends to 2 mm x 45°
• Check the thread with screw pitch gauge.
• Hold the job at 90° in bench vice.
• Repeat the thread cutting process until the nut
• Set M14 split die in die stock. matches.
• Set the die on the blank end and press down evenly • Apply a little oil and preserve it for evaluation.
and turn in clockwise direction slowly to cut thread.
Use cutting lubricant while cutting thread
• Check the die 90° to the cylindrical rod.
• Apply pressure evenly on the die stock and turn in a
clock wise direction to advance the die in cylindrical
blank.
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Fitter - Drilling
Prepare nuts and match with bolts

• cut and file square rod to blank size to cut external threads
• file square bolt and nut to correct size and shape as per drawing
• determine tap drill sizes for hexagonal and square nut
• drill holes for tapping holes, to cut internal threads in hexagon and square nut
• cut external threads on square head bolt using die and die stock
• cut internal threads on hexagon and square nuts using tap and tap wrench
• match nuts with bolts.
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Job Sequence
PART - 1 Hexagonal head bolt
Note: Use Ex:No 2.1.69 Task 2 hexagonal bolt for matching • Similarly, fix M10 second tap, third tap and cut and
with hexagonal nut. form the full thread.
Hexagonal nut • Check the threaded hole with screw pitch gauge and
matching bolt.
• Check the raw material for its size
• Clean the thread in bolt and nut.
• File nut to size 10 mm thickness in 18 mm across flat
hexagonal rod • Match the nut with bolt as shown in Fig 1.
• File chamfer in one end to 2 mm x 30°
• Determine tap drill size for M 10 tap.
• Mark centre of hole for tap drill size Ø 8.5 mm
• Punch on tap drill hole centre with centre punch 90°
• Make centre drill to locate hole centre
• Drill pilot hole Ø 5 mm in hexagonal nut
• Drill Ø 8.5 mm hole for M 10 tap.
• Chamfer both ends of drilled hole to 2 mm x 45°
• Hold the nut in bench vice parallel to vice jaws.
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•
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Fix M10 first tap in tap wrench and cut internal thread
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as per drawing. • Apply a little oil and preserve it for evaluation.
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PART - 2 Square head bolt

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• Cut the square rod to size 53mm. • Make centre drill to locate hole centre.
• File square rod side 25 mm to side 24 mm and length • Drill Ø 6 mm pilot hole in square nut
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50 mm.
• Drill Ø 10.5 mm for tapiping hole.
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• File to size Ø 11.9 mm x 50 mm length as shown in

fig 2. • Chamfer both ends of drilled hole to 2 mm x 45°
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• File chamfer in blank end to 2 mm x 45° and head side • Hold the nut in bench vice parallel to vice jaws.
2 x 30° • Fix M 12 first tap in tap wrench and cut internal thread
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• Hold the square head bolt blank in bench vice to 90° as per drawing.
• Fix M 12 split die in die stock. • Similarly, fix M 12 second tap, third tap and cut and
form full internal thread.
• Set M 12 split die on square head bolt blank end and
cut external thread. • Check the threaded hole with screw pitch gauge and
matching bolt.
• Repeat the thread cutting process untill the nut
matches. • Clean the thread in bolt and nut.
• Check the external thread using screw pitch gauge • Match the nut with bolt as shown in Fig 2.
and matching nut. • Apply a little oil and preserve it for evaluation.
Square Nut
• Check the raw material size 15mm.
• File nut to size 12 mm thickness in 25 mm side square
rod.
• File chamfer in one end to 2 mm x 30°.
• Determine tap drill size for M 12 tap.
• Mark centre of hole for tapping hole.
• Punch on the tap drill hole centre with centre punch
90°
Fitter - Drilling
File and make step fit, angular fit, angle, surfaces (bevel gauge accuracy 1
degree)
• mark off lines using vernier height gauge
• file steps maintaining accuracy ± 0.04 mm
• mark 45° angle using vernier bevel protractor
• file angle maintaining 1°accuracy
• make step and angular fit, finish and de - burr.
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Job Sequence
PART - 1
parallelism and perpendicularity.
• Mark and punch in part ‘1’ as shown in fig - 1.
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• Drill Ø 3 relief holes as shown job drawing.
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• Chain drill holes for parting off excess material from
part ‘1’ as shown in Fig 2.
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• Cut and remove excess material using web chisel and

ball pein hammer.
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• File steps to size maintaining accuracy ± 0.04 mm

and angle to 45° maintaining 1° accuracy using safe
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• Check the size with vernier caliper and angle with bevel
edge different grades of files as shown in Fig 3. gauge.
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• Mark and punch in part -2 as shown in Fig 4.
• Cut and remove excess material using web chisel and

ball pein hammer.
• File steps to size and angle to 45° using safe edge
file different grades as shown Fig 6.
• Drill Ø 3 relief holes as shown in drawing. • Check the size with vernier caliper and angle with bevel
• Chain drill holes for parting off excess material from gauge.
part - 2 as shown in Fig 5. • Match part 1 and 2 as shown in Fig 7.

• Finish file on part 1, 2 and de - burr in all the surfaces. • Apply a little oil and preserve it for evaluation.
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Fitter - Drilling
Make simple open and sliding fits

• file flat surfaces to flat and parallel within an accuracy of ± 0.04 mm
• file and assemble the tongue and groove, and obtain the required class of fit.
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42
Job Sequence
Part - A

• Apply marking media, mark as per job drawing and
punch witness marks in part A as shown in Fig 1.
• Similarly cut and remove the excess metal and file

step B to size and shape and check the size with vernier
caliper as shown in Fig 3.
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Drill relief hole Ø 3 mm as per job drawing in part A.
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• Mark lines as shown in Fig 2 leaving the metal 1 mm

away from the object line and cut and remove the excess
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metal by hacksawing.
• File part A as per drawing to size 14 mm x 24 mm with
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safe edge file and check the size with vernier caliper.
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Part B
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• Apply marking media, mark and punch as shown in
Fig 4.
• File to size and shape maintaining the flatness and

squareness as shown in Fig 6.
• Match part ‘A’ and ‘B’ as shown in Fig 7
• Drill relief hole Ø 3 mm on part B
• Finish file and de - burr in all the surfaces of the job.
• Chain drill holes, chip, hacksaw and remove the excess
metal as shown in Fig 5.
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Fitter - Drilling
Enlarge hole and increase internal dia

• mark drill hole centre as per drawing
• drill centre drill and pilot hole
• enlarge the drilled holes to Ø 25 mm.
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45
Job Sequence
• File and finish to size 80x63x9 mm and maintaining
• Apply marking media, mark off centre lines and locate
the centre of drill hole as per drawing.
• Punch on the intersecting lines using prick punch 30°,
set 12.5 mm in divider using steel rule and draw
Ø 25 mm circle as shown in Fig 1.
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Fix the job on the drilling machine table.
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• Fix centre drill in drill chuck and locate the drill hole in
centre of the work piece. (Fig 2)
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• Finally, enlarge the previously drilled hole to Ø 25 mm

as shown in Fig 5.
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• Fix Ø 6 mm drill in drilling machine and drill pilot hole

in the centre drilled hole. (Fig 3)
• set the drilling machine speed according to the diameter
of drill. • Finish file on the job and de-burr in all the surfaces.
• Similarly, fix Ø 10 mm, Ø 16 mm and Ø 20 mm drills in • Apply a thin coat of oil and preserve it for evaluation.
different diameters one by one in drilling machine and
enlarge the previously drilled holes as shown in Fig 4. Use coolant while drilling

Fitter - Drilling
File cylindrical surfaces

• hold cylindrical rod in a bench vice
• file cylindrical surface maintaining ± 0.04 mm in diameter
• finish and de - burr.
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Job Sequence
• File round rod both ends to flatness and squareness
maintaining 75 mm length.
• Check the flatness and squareness with try square.
• Apply marking media in both ends of round rod.
• Mark the diameter Ø 25 mm on both ends using divider
and steel rule to file cylindrical profile as shown in
fig 1.
• Punch witness marks on marked diameter.
• Hold the cylindrical rod in bench vice and file cylindrical
profile to Ø 25 mm using flat file of different grades in • Rotate the cylindrical rod and file circular profile to
see saw motion. Ø 25 mm.
• Check the length and diameter of cylindrical rod with • Check the diameter with out side micrometer.
vernier caliper. • Debur in both ends of round rod.
• Apply little oil and preserve it for evaluation.
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Fitter - Drilling
Make open fitting of curved profiles

• file surfaces to flat and parallel to an accuracy of ± 0.04 mm
• mark curved profiles as per drawing
• file radius and curved profiles to size and shape
• match open fitting of curved profile.
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Job Sequence
• Check the raw matel size using steel rule.
PART - 1
• File and finish to overall size 64 x 57 x 9 mm
• Apply marking media, mark in part 1 as per job drawing.
• Punch witness marks as shown in Fig 1
• Cut relief grooves by hacksaw.
• Cut and remove the hatched portion of excess metal

on curvature side (fig 4) and file the curved profile to
size and check the curved profile with template and
check the sizes with vernier caliper as shown in Fig 5.
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• Cut and remove the hatched portion of excess metal in
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one side and file to size and shape as shown in Fig 2.
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• Similarly, cut and remove the hatched portion of excess
metal on otherside and file to size and profile as shown
in Fig 3.
Part - 2
• Apply marking media, mark as per job drawing.
• Punch witness marks in part 2 as shown in Fig 6.
• Chain drill holes to remove excess metal as shown in

Fig 7.
• Cut and remove the hatched portion of excess metal
and file to size and shape as shown in Fig 8.

• Check the curved profile with template and the
size with vernier caliper as shown in Fig 10.
• Match part 1 and 2 as shown in Fig 11 & 12 in both

sides.
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Similarly, cut and remove the hatched portion of excess
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metal on curved profile side with hacksaw and file the
profile to size and shape as shown in Fig 9.
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• Finish file in part 1 and 2 and remove burrs in all the

surfaces and corners.
• Apply a little oil and preserve it for evaluation.

Fitter - Drilling
Correction of drill location by binding previously drilled hole

• prepare round rod more than the hole size
• plug the hole as tight fit
• file the plugged surface on both sides flat and square
• mark the hole location concentricity to centre lines
• drill pilot and correct drill hole concentricity to the centre lines.
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Job Sequence
• Check the given material hole size Fig 1. • Punch on the drill hole centre mark with centre punch
90°.
• Fix centre drill in drill chuck and make centre drill hole.
• Fix Ø 6 mm drill and drill hole as a pilot hole (Fig 3).
• Similarly fix Ø 9 mm, Ø 13 mm drill and enlarge the
previously drilled holes.
• Prepare round rod more than 0.050 mm actual size of

drilled hole (16.000 + 0.050 = 16.050 mm)
• Plug the hole as tight fit with prepared round rod using
ball pein hammer (Fig 2)
• Finally, fix Ø 16 mm drill and enlarge the previously
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drilled hole Fig 4.
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• File the plug surface on both sides to flat and square.

• Apply marking media on surface.
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• Mark correct centre for drill hole with vernier height

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gauge (Fig 3) • Finish file, de-burr, clean and check with vernier caliper.

Fitter - Drilling
Make inside square fit

• mark the dimension lines as per drawing
• chain drill, cut and remove excess metal by chipping
• file square slot maintaining ± 0.04 mm
• match square in square slot.
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Job Sequence
PART - 1
• Check the given raw material for its size.
• Rough and finish file on surfaces flat and square to
over all size 70x70x11 mm maintaining accuracy
± 0.04mm.
• Mark off sizes in part 1 as per job drawing and punch
witness marks.
• Hold part 1 in drilling machine table and drill chain drill
holes to remove excess metal as shown in Fig 1.
• File the chipped portion to size and shape using safe

edge file of different grades maintaining accuracy of
± 0.04 mm and check the size with vernier caliper.
• Cut relief grooves using hacksaw at four inside corners
as shown in Fig 3.
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Pheriphery of the drill should not touch the
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witness marks
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• Cut and remove the chain drilled hatched part using

web chisel and ball pein hammer as shown in Fig 2.
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PART - 2
• File to size 30x30x11 mm maintaining accuracy ±
0.04 mm.
• Check the flatness and squareness with try square.
• Match part - 2 into part1 as shown in Fig 4.
• Finish file in part 1 and 2 with flat smooth file and
de-burr in all the surfaces and corners of the job.

Fitter - Fitting assembly
Make sliding ‘T’ fit

• file flat surfaces to flat and square maintaining accuracy ± 0.04 mm
• mark dimension lines as per drawing
• file to size, shape and make sliding fit.
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Job Sequence
• Check the raw matal size using steel rule. • Hacksaw and remove the hatched portion of excess
metal in one side of the job as shown in Fig 2.
PART - 1
• File and finish to overall size of 62x60x14 mm
maintaining parallelism and perpendicularity and to the
accuracy of ± 0.04 mm.
• Apply marking media, mark as per drawing and punch
witness marks as shown in Fig 1.
• File the cut portion to size and shape maintaining

flatness and squareness to the accuracy of ± 0.04mm.
• Similarly, cut and remove the excess metal in other
side, file and check the size with vernier aliper as shown
in Fig 3.
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• File and finish to size 62x60x14 mm maintaining

parallelism and perpendicularity to the accuracy of
± 0.04 mm
• Apply marking media, mark and punch the dimension
lines as shown in Fig 4.
• Hacksaw chip and remove the hatched portion of
excess metal as shown in Fig 5.
• File to size and shape maintaining flatness and
squareness as shown in Fig 6.
• Match part 1 and 2 and slide it as shown in Fig 7.
• Finish file part 1 and 2 and de-burr all the surfaces and
corners of the job.
• Apply a little oil and preserve it for evalluation.

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File fit - combined, open angular and sliding sides

• file surfaces flat and square to the accuracy of ± 0.04 mm
• file flat and angular surfaces as per drawing
• measure the angle using vernier bevel protractor
• fit combined open, angular sliding sides, finish and de-burr.
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Job Sequence
• Check the raw matal for its size.
• File part 1 and 2 to over all size 78 x 48 x 9 mm
• Apply marking media and mark dimension lines on part
1 and 2 as per job drawing.
• Punch witness marks on part 1 and 2.
• Hacksaw and remove the excess metal in part 1 and
file to size and shape maintaining accuracy ± 0.04 mm
and angle 30 minutes as shown in Fig 1.
• Match part 1 and 2 as shown Fig 3.
• Apply a little oil and perserve it for evaluation.
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• Drill Ø 3 mm relief hole in part ‘B’

• Chain drill, chip, remove the excess metal in part ‘B’
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and file to size and shape as shown in Fig 2.

• Check the size with vernier caliper and angles with
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vernier bevel protector.

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• Finish file on part 1 and 2 and de-burr in all corners.

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File internal angles 30 minutes accuracy open, angular fit

• file surfaces parallel and square within an accuracy of ± 0.04 mm
• mark dimension and angular lines as per drawing
• file flat and angular surfaces as per drawing
• check the angle using vernier bevel protector to an accuracy of 30 minutes
• fit angular surfaces as per drawing, finish and de-burr.
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Job Sequence
• Check the raw material size.
• File part 1 and 2 to over all size 74 x 47 x 9 mm
maintaining flat and squareness.
• Apply marking media on the surface and mark
dimension lines on part 1 and 2 as per job drawing.
• Punch witness marks on part 1 and 2.
• Drill Ø 3 mm relief holes in part 1 and 2.
• Hacksaw and remove the excess metal in part 1 and
• Match part 1 and 2 as shown in Fig 3.
file the cut portion to size and shape maintaining the
accuracy ± 0.04 mm and angles 30 minutes as shown • Apply a little oil and preserve it for evaluation.
in Fig 1.
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• Chain drill, chip, hacksaw and remove the excess metal
in part 2 and file to size and shape as shown in Fig 2.
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• Check the size with vernier caliper and angles with

vernier bevel protector.
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Make sliding fit with angles other than 90°

• file and finish flat and angular surfaces within an accuracy of ± 0.04 mm and ± 30 minutes
• mark and drill holes as per drawing
• cut internal thread to assemble countersink screws
• prepare and assemble components using screws and dowel pins
• assemble components to achieve sliding fit with angular mating surfaces.
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Job Sequence
• Check the raw material for its size. • Drill free hole Ø 5.5 mm for CSK screw in part 2 and 3.
• File the material of part 1, 2, 3 and 4 to over all sizes • Counter sink the drilled holes to seat the counter sink
maintaining the accuracy of ± 0.04 mm. head screws in part 2 and 3.
• Apply marking media on part 1, 2, 3 and 4 surfaces • Hold the part 1 in bench vice.
and mark lines as per drawing. • Cut internal thread using M5 hand tap and tap wrench.
• Punch witness marks. • Clean the threads with out burrs.
• Hacksaw and file in part 2, 3 and 4 and file to size and • Cut and file in part 2, 3 and 4 to size and shape as per
shape as per job drawings. job drawing and check the size with vernier caliper and
• Assemble and clamp part 1,2,3 and 4 together in drilling angles with vernier bevel protractor.
machine table with parallel clamps as shown in Fig 1. • Assemble part 1,2,3 and 4 as per job drawing along
with dowel pins and counter sink screws.
• Fit and slide part 4 in the assembly as shown in Fig 2.
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• Fix Ø 3.8 mm drill in drilling machine spindle through

drill chuck and drill through hole.
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• Fix Ø 4 mm hand reamer in tap wrench and ream the

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drilled hole to fix Ø 4 mm dowel pin without disturbing

the assembly setting.
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• Clean the reamed hole and insert Ø 4 mm dowel pin.

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• Similarly, drill other dowel pin holes one by one and

ream the drilled hole one by one and fix the dowel pins • Disassemble all the parts from assembly.
without disturbing the assembly. • Finish file on part 1,2,3 and 4 and remove burrs in all
• Fix Ø 4.2 mm drill in drilling machine spindle through the corners of the job.
drill chuck and drill holes for cutting internal thread to • Re-assemble all the parts together as per job drawing.
fix counter sink screws in assembly without disturbing
the setting.
• Seperate the assembly parts 1,2,3 and 4 and chamfer
the tapping holes both ends in part 1 using countersink
tool.

Scrap on flat surfaces, curved surfaces and parallel surfaces and test
• file surfaces flat and square to the accuracy of ± 0.04 mm
• find high spots on flat and curved surfaces using prussion blue
• scrap on flat, curved surfaces and test.
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Job Sequence
TASK 1: Scraping on flat surface
• File metal to size 96x96x10 mm maintaining flatness
and squareness.
• Clean the surface plate with soft cloth.
• Apply prussion blue evenly on the surface plate.
• Place the job on surface plate and move slightly forward
and backward
• Take the job from surface plate and notice the blue
spotted marks on the flat surface.
• Hold the job in bench vice • Repeat the scraping process untill the prussion blue
• Scrap and remove the high spots on the flat surface of spotted marks spread over the entire surface of the
the job using flat scraper Fig1. job.
• Wipe off the scraped surface with soft cloth to remove • Wipe off the scraped surface with soft cloth.
burrs. • Apply thin coat of oil and pressure it for evaluation.
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• Again, place the scraped surface on prussion blue
applied surface and move forward and backward and
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notice the high spot marks.
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TASK 2: Scraping on curved surface

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• File metal to size 90x48x18 mm maintaining flatness

and squareness.
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• Apply marking media, mark and punch as shown

in Fig 1.
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• Chain drill holes remove excess material as shown in

Fig 2.
• Cut and remove the hatched portion of chain drilled
holes excess metal using web chisel and ball pein
hammer as shown in Fig 3.

• File curved surface with half round file and check the • Scrap and remove the high spots on the curved profile
curved profile with template. surface using half round scraper.
• Hold the round test bar in bench vice along with • Wipe off the scraped surface with soft cloth to remove
aluminium vice clamps. burrs.
• Apply thin coat of prussion blue on the one end of • Again, apply prussion blue on the test bar and place
cylindrical surface of test bar. the curved scrapped surface on test bar and rotate back
and forth.
• Place the curved surface of the job on prussion blue
applied test bar and rotate back and forth. • Repeat the scrapping process untill the prussion blue
spotted marks spread over the entire curved surface of
• Notice the blue spotted marks on curved surface.
the job.
• Hold the job in bench vice.
• Wipe off the scraped surface with soft cloth.
• Apply thin coat of oil and presserve it for evaluation.
Skill sequence
Scraping curved surfaces

• scrap and test curved surfaces.
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A half round scraper is the most suitable scraper for
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scraping curved surfaces. This method of scraping differs
from that of flat scraping.
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Method
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For scraping curved surfaces the handle is held by hand

in such a way as to facilitate the movement of the scraper
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in the required direction. (Fig 1) During the forward movement one cutting edge acts, and
on the return stroke, the other cutting edge acts.
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After each pass, change the direction of cutting. This

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Pressure is exerted with the other hand on the shank for

cutting.
Rough scraping will need excessive pressure with longer

strokes.
For fine scraping, pressure is reduced and the stroke length

also becomes shorter.
Cutting action takes place both on forward and return

strokes. (Fig 2)

Use a master bar to check the correctness of the surface
being scraped. (Fig 5)
Apply a thin coating of Prussion blue on the

master bar to locate the high spots.
Sharpening a flat scraper

• sharpen a flat scraper by grinding and honing.
Flat scrapers are sharpened by grinding the cutting edge Move the scraper in an arc to provide a slightly concave
and honing both faces. surface on the cutting edge. (Fig 3)
To avoid overheating while grinding, use wet wheel grinding
or ensure that there is a cooling arrangement for the
pedestal/bench grinder.
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Select a grinding wheel with fine grain. (Fig 1)
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If the scraper is carbide-tipped use silicon carbide

or diamond wheels. (Fig 4)
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The cutting edges sharpened by grinding should be honed.

Honing removes grinding marks and provides keen cutting
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edges.
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Soft grade aluminium oxide grinding wheel with large

diameter gives best results.
Check for gap between the work-rest and the
grinding wheel, and adjust, if neessary.
For grinding the cutting edges, hold the scraper horizontal Use a fine grade aluminium oxide oilstone for honing.
and flat on the tool rest. (Fig 2) While honing use a lubricant.
Mix light mineral oil with kerosene for preparing the
lubricant.
Hone the faces first with a movement as shown in Fig 5.
Then hone the cutting end by placing the scraper in an
upright position on the oilstone with a rocking movement.
(Figs 6 and 7)
What should be the cutting angle? It should be
- for rough scraping - 60o
- for final scraping - 90o.
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Sharpening half round scrapers
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• sharpen a half round scraper.
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Scrapers are usually re-sharpened on oilstones. When Grind the bottom surfaces with a slight curve. This helps
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cutting edges are badly damaged, they are ground on the cutting edges to make point contact on the surfaces
pedestal grinders. being scraped. (Fig 3)
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Sharpening half round scrapers

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Half round scrapers have two cutting edges on the rounded

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back. (Fig 1)
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Rub the bottom surface with a rocking motion on the

olistone for re-sharpening. (Fig 4)
The cutting edges are formed by the bottom surface, and

the flat surfaces are ground on the rounded back of the
scraper. (Fig 2)
When the cutting edge is blunt it can be re-sharpened by

grinding the bottom surface.
As far as possible avoid grinding of the edges.

(Flat surface ground on the rounded back.)

Make and assemble, sliding flats, plain surfaces

• file surfaces to flat and square to the accuracy of ± 0.04 mm
• prepare all the parts as per drawing
• drill dowel pin holes, counter sink screw holes
• assemble and slide flat in plain surfaces.
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Job Sequence
• Check the raw material for its size. • Seperate the assembly parts 1,2 3,4 and chamfer the
tapping holes both ends in part 1 using countersink
• File job for part 1,2 3 and 4 to size and shape as per tool.
drawing.
• Hold part 1 in bench vice.
• Apply marking media on part 2 and 3 and mark to locate
the dowel pin holes, countersink screw holes as per • Drill free hole Ø 5.5 for countersink screw on part 2and
drawing. 3 and countersink the hole to seat ountersink head
screw .
• Assemble and clamp part 1,2 3 and 4 together in drilling
machine table with parallel clamps as shown in Fig 1. • Cut internal thread using M5 hand tap and tap wrench.
• Clean the thread without burrs
• Assemble part 1, 2,3 and 4 as per job drawing along
with dowel pins and countersink screws.
• Fit and slide part 4 in the assembly as shown in Fig 2.
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drill chuck and drill through hole.
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• Fix Ø 4 mm hand reamer in tap wrench and ream the

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drilled hole to fix Ø 4 mm dowel pin without disturbing

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• Clean the reamed hole and insert Ø 4 mm dowel pin.

• Disassemble all the parts from assembly.
• Similarly, drill holes for other 3 dowel pin holes one by
one and ream the drilled holes one by one and fix the • Finish file on the surface of part 1,2,3,4 and remove
dowel pins without disturbing the assembly. burrs in the corners of the job.
• Fix Ø 4.2 mm drill in drilling machine spindle through • Re-assemble all the parts together as per job drawing.
drill chuck and drill holes for tap drill holes for fixing • Apply thin film of oil and preserve it for evaluation.
counter sink screws in assembly without disturbing
the setting.

Check for blue math of bearing surfaces - both flat and curved surfaces by
whitworth method
• apply prussion blue on surface plate and cylindrical test bar
• check the blue math of high spots on flat surface using surface plate
• check the blue math of high spots on curved surface using test bar.
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Job Sequence
TASK 1: Checking blue math on flat surface
• Use exercise no:2-2-83 Task 1 job for this exercise. • Place the job on the surface plate
• Clean the surface plate with soft cloth. • Move slightly forward and backward and notice the blue
math spreaded over entire the flat surface.
• Apply prussion blue evenly on the surface plate.
TASK 2: Checking blue math on curved surface

• Use exercise no: 2-2-83 Task 2 job exercise. • Apply prussion blue evenly on the curvature of the test
bar.
• Clean the cylindrical test bar with soft cloth.
• Place the curved surface of the job on test bar and
• Hold the test bar in bench vice along with aluminium
rotate slightly on back and forth.
vice clamp.
• Notice the blue math spreaded over the entire curved
surface.
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File and fit combined radius and angular surface (accuracy ± 0.5 mm) angular
and radius fit
• file flat and parallel surface to an accuracy of ± 0.04 mm
• chain drill, chip to remove excess material
• file dovefail and curved profile as per drawing and check the angles with vernier bevel protractor and curved
surface with template
• fit combined radius and angular surface.
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Job Sequence
• Check the raw matel size using steel rule. • File to size maintaining accuracy of ± 0.04 mm for
linear dimension and 30 minutes accuracy for angular
PART A dimesion.
• File and finish to overall size of 74x60x9 mm maintaining • Check the size with vernier caliper and angle with vernier
parallelism, perpendicularity and to the accuracy of bevel protector.
± 0.04 mm
• Similarly, cut and remove excess metal in other side
• Check the size with vernier caliper. and file to size and shape as shown in Fig 3.
• Cut and remove the excess metal in curvature side

and file curved profile to size and shape as shown in
Fig 4.
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• Drill relief holes Ø 3 mm as shown Fig 2. • Check the curved profile with template.
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•
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Hacksaw and remove the hatched portion of excess
metal in one side as shown in Fig 2.
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PART B
• File and finish to overall size of 74x50x9 mm maintaining • Drill relief holes Ø 3 mm and drill chain drill holes to
parallelism and perpendicularity and to the accuracy remove excess metal as shown Fig 6.
of ± 0.04 mm.
• Hacksaw, chip and remove the hatched portion of

excess metal and File the chipped portion to size and
shape as shown in Fig 7.

• Check the curved profile with template.
• Match part A and B as shown in Fig 10 and 11
• Finish file in part A,B and remove the burrs in all the
corners.
• Hacksaw and remove the hatched portion of excess

metal on curved surface shown in Fig 8.
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• File the curved portion to size and shape as shown in
Fig 9.
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• Apply a little oil and preserve it for evaluation

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Locate accurate holes and make accurate hole for stud fit
• file surfaces flat and square
• determine tap drill size for tapping hole and drill the hole
• cut M10 internal thread using tap with wrench
• fit stud in the threaded hole.
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80
Job Sequence
• Check the raw material for its size. • Check the thread with screw pitch gauge.
• File metal to size 48x48x9 mm maintaining flatness • Fit stud in the threaded hole Fig 1.
and squareness. • Apply a little oil and preserve it for evaluation
• Mark drill hole at the centre of the job as per drawing.
• Determine the tap drill size for M10 tap.
• Hold job in bench vice
• Fix centre drill in drill chuck and drill centre drilling to
locate the drill hole centre.
• Similarly, fix Ø 6 mm drill and drill pilot hole.
• Fix Ø 8.5 mm drill and drill through hole for tapping.
• Chamfer on both ends of the drilled hole using
countersink tool.
• Hold the job in bench vice.
• Cut M10 internal thread using hand tap and tap wrench.
• Clean the thread to remove the burrs.
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Fasten mechanical components/sub-assemblies together using screws,

bolts and collars using hand tools
• file surface flat and square
• mark drill holes as per drawing
• cut M6 internal thread using hand tap and tap wrench
• assemble together all the parts as per drawing.
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82
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Job Sequence
• Use Ex: No 2.1.68 for part 1 and Ex.No 2.1.69 part • Check the size with vernier caliper.
2 for part 3. • Clean the parts 1,2 and 3.
Prepare collar: (Part 2) • Assemble the parts 1 and 2 using hexagonal bolt and
• Check the raw material size. tighen the bolt using suitable double ended spanner/
ring spanner.
• File flatness and squareness
• Mark the tap drill hole centre on middle of the collar as
• Mark in collar as per job drawing and punch the hole
shown in job drawing
centre and the outer circumference of collar.
• Set the assembly in drilling machine table using suitable
• Drill the centre of hole Ø 10.5 mm and counter sink the
clamping device.
drilled hole both sides.
• Make drill hole collar Ø 5.2 mm for M6 tap and drill
• Hold the job in bench vice and file the circumference of
upto the depth of 3 mm in hexagonal bolt as shown in
collar to Ø 22 mm and thickness 14 mm.Fig 1
job drawing.
• Seperate the parts 1,2, and 3.
• Fix counter sink tool in drilling machine and chamfer
the Ø 5.2 mm drilled hole.
• Hold the collar in bench vice
• Cut M6 internal thread using hand tap and tap wrench.
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• Enlarge the Ø 5.2 mm already drilled hole to Ø 6 mm x
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hexagon bolt using suitable double ended spanner /
ring spanner.
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• Screw the round head slotted screw in collar as shown

job drawing and make it tight using suitable screw driver
and complete the sub-assemblies.
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• Apply thin coat of oil and preserve it for evaluation.

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Make sliding fits assembly with parallel and angular mating surface
• file surface flat and parallel to the accuracy of ± 0.04 mm
• file and prepare all the parts for assembly
• drill holes for dowel pins and countersink screws
• assemble components using dowel pins and counter sink screws
• fit and slide the angular mating surface, finish and de-burr.
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85
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Job Sequence
• File the materials for part 1,2,3 and 4 to overall sizes
maintaining the accuracy ± 0.04 mm.
• apply marking media on part 2,3 and 4 and mark linear
dimensional lines with vernier height gauge and angular
lines with vernier bevel protector.
• Punch witness marks on part 2,3 and 4.
• Punch on drill hole marks for dowel pins and counter
sink screws assembly using centre punch.
• Cut and remove the excess metal from part 2,3,4 and
file to size and shape as per job drawing and check
the size with vernier caliper and angles with vernier
bevel protractor. (Fig 1)
• Similarly, drill for other dowel pin holes one by one and
ream drilled holes to fix Ø 4 mm, 3 dowel pins, one by
one without disturbing the assembly setting.
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• Determine tap drill size for M4 internal thread
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drawing.
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• Seperate the assembly part 1,2,3 and 4.

• Assemble and clamp part 1,2 and 3 together in a drilling
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machine table with parallel clamps as shown in Fig 2. • Fix counter sink tool in drilling machine and chamfer in
both ends of drilled holes to cut internal thread in
part 1.
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drill chuck and drill through holes for dowel pin

assembly. • Hold the part 1 in bench vice and cut internal thread
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using M4 tap and tap wrench.

• Fix Ø 4 mm hand reamer with tap wrench and ream
the drilled hole to fix Ø 4 mm dowel pins without • Fix counter sink tool and counter sink the drilled holes
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disturbing the assembly setting. in part 2 and 3 to seat the counter sink head screws.
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• Clean the reamed hole with soft cloth and insert • Finish file on part 1,2,3, 4 and remove burrs in all corners
Ø 4 mm dowel pin. of the job and assemble the parts all together using
dowel pins,counter sink screws as shown in job drawing.

Fitter - Turning
Lathe operations
Objective: At the end of this exercise you shall be able to
• record the different lathe operations in table 1.
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89
Note: Instructor shall demonstrate to the
trainees regarding the different lathe operation
performed in lathe.
Record the lathe operations in Table 1
TABLE 1
Fig.No. Name of the operation

1
2
3
4
5
6
7
Get it verified by your instructor.
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Fitter - Turning
True job on four jaw chuck using knife tool

• set the round rod/job in four jaw chuck
• true the round rod/job using knife tool.
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91
Job Sequence
• Open one jaw by chuck key. • Check the job trueness by knife tool.
• Turn the chuck and open the opposite jaw • Tighten all the jaws.
• Open all jour jaws approximately more than job diameter • Check the truness of the job by rotating the chuck in
neutral position using knife tool.
• Keep the job inside the jaws
• Knife tool should touch the job evenly.
• Make jaws close and hold the job
• Check once again for the true running of the job.
Skill Sequence
Truing work in a four jaw chuck with the help of a surface gauge
• true a round rod in a four jaw independent chuck with the help of a surface gauge.
If truing is not done before turning, the following will be the

results.
Uneven load on the cutting tool.
For the same depth more metal will be removed from the
out of centre portion.
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Surface turned may not be cylindrical.
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During truing
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Keep the main spindle in a neutral position.

Measure the job diameter with an outside caliper or with a
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steel rule. (Fig 1)

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Position the four jaws of the independent chuck, equidistant

from the centre. The distance between the inner face of
the opposite jaws is equal to the diameter of the work.
(Fig 2) Rotate the chuck by hand and observe the gap between
the tool and work surface for the position of the two opposite
Open the adjacent jaws sufficiently enough to insert the jaws.
work. (Fig 3)
Open the jaw slightly where the gap is more, and tighten
Place the work inside the chuck, keeping sufficient portion the opposite jaw. (Fig 4).
outside the chuck for turning, and tighten the two adjacent
jaws, enough to grip the work.
Fix the knife tool on the bed-ways close to the chuck.
Adjust the tool to make its tip move close to the top or
side portion of the work with a minimum gap.

Repeat the above sequences for the other set of opposite
jaws.
Bring the tool point tip closer to the work surface.
Rotate the chuck by hand and observe the gap.
Engage the spindle levers at about 250 rpm and run the
machine.
Touch the tool point on the job.
If the line on the job is uniform tighten the jaw.
Repeat till a uniform line is formed.
Finally, tighten the opposite jaws with the same amount
of pressure.
Repeat until the gap is the same. (Fig 5) Check once again for the true running of the work.
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Fitter - Turning
Face both the ends for holding between centres

• set the job on a four jaw chuck
• set the tool on the tool post
• face the job
• measure the length with vernier caliper.
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94
Job Sequence
• Check the raw material for its size. • Reverse the job, clamp it in the chuck and true it again.
• Hold the job in a four-jaw independent chuck with 25 mm • Set the spindle speed closer to 318 revolution per
overhang and true it. minute.
• Set the R.H. facing tool in the tool post. • Face the length up to the half punch mark level and
maintain 250 mm long.
• Set the R.P.M.
• deburr and check the job.
• Face one end of the work.
• Mark the job 250mm long and punch witness marks on
the circumference.
Skill Sequence
Finish-facing the work with a right hand facing tool

• finish-facing the work using a right hand facing tool.
When more metal is to be removed on the face of work, we Feed the tool about 0.5 mm by the top slide.
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prefer to do rough facing by an L.H. facing tool or a L.H.
Feed the tool towards the centre of the work by the cross-
roughing tool, feeding the tool from the periphery of the
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work towards the centre. Finish-facing is done to get a
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better surface finish on the face of the work by removing the
back the tool to the starting position (Fig. 2a).
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rough facing. The normal R.H. facing tool, having its cutting
edge straight, may be kept slightly inclined to the face of
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the work during facing. A tool, having its cutting edge itself
ground at an angle, may be used. (Fig.1)
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The procedure of the finish-facing the work with such a tool

is given in sequence below.
Advance the tool by a further 0.5 mm inside the work by the
Hold the tool in the tool post to the correct centre height top slide.
with its axis at right angles to the axis of the work and with
a minimum overhang. Engage the power feed (set at 0.05 mm/rev.) and allow the
tool to travel towards the centre of the work, removing the
Set the machine to about 500 rpm. (Calculate the spindle metal.
speed by choosing the recommended cutting speed for
finish-facing and the mean diameter of the work). Repeat the sequence until the required amount of material
is removed.
Start the machine and touch the tool point to the work-face
by moving cross slide and carriage movement. Move the Observe the finish obtained.
tool away from the work (Fig 2a) and set the top slide
graduated collar to zero, eliminating backlash. Lock the
carriage.

Fitter - Turning
Using roughing tool parallel turn ± 0.1 mm

• hold the work in lathe chuck
• grind RH turning tool
• set the turning tool in tool post
• set the machine spindle speed for turning
• parallel turn the work by hand feed method with various depths of cuts.
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Job sequence
• Hold the work in four jaw chuck. • Reverse the job and hold in four jaw chuck.
• Grind and fix RH turning tool and turn ∅36 to maximum • Turn the remaining length to ∅36 mm by parallel
length of job with the R.P.M. close to 318. turning.
• Check the diameter by using vernier caliper • Chamfer the end and deburr.
• Chamfer the end 3×45° and deburr.
96
Skill Sequence
Rough turning tool grinding

• grind rough turning tool with various angle.
• Rotate the wheel by hand and observe for free rotation. • Finish grind all the faces on the finishing wheel.
• Check the grinding wheels for true running. • Grind a nose radius of approximately R. 0.4 mm.
• Wear goggles. • Check the angles with a tool angle gauge and template.
• Dress the wheels by a wheel dresser. • Lap the cutting edge with a oilstone.
• Adjust the tool-rest to maintain a minimum gap from the • The top rake (back rake) angle should be kept at 0°.
wheel face to a minimum of 2 to 3 mm.
• Hold and apply the side flank of the tool to the front face
of the grinding wheel at 30° to horizontal.
• Move the tool left to right and vice versa to grind the side
cutting edge angle to cover 2/3rd width of the tool.
• Grind a side clearance angle of 8°, the bottom of the
edge touching the wheel first.
• Rough grind the end cutting edge angle of 30° and the
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front clearance angle of 5° simultaneously.
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• Hold the top flank of the tool against the wheel face
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inclined at 14°, the rear the side contacting the wheel
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first, and grind the side rake angle of 14°.

• Ensure that the ground portion is parallel to the side
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cutting edge.
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Fitter - Turning
Measure the diameter using outside caliper and steel rule

• check the diameter using outside caliper
• measure diameter with steel rule.
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98
Job Sequence
• Adjust the caliper legs to just touch outer diameter of
• Hold the out side caliper
the job.
• Open the caliper legs approximately more than job
• Repeat the same procedure in different position of the
diameter
job
• Adjust the outside caliper leg to touch the diameter of
• Measure the diameter by using steel rule.
the job.
Skill Sequence
Measuring with outside calipers
• select the right capacity caliper for measurement
• set the sizes both in firm joint and spring calipers
• read the sizes by transferring them to a steel rule or other precision measuring devices as the case may be.
Outside calipers Because the accuracy of reading the sizes depends mainly
upon the sense of feel of the user, high care should be
Select a caliper based on the diameter to be measured.
exercised to get the correct feel. (Fig 3)
A 150 mm capacity outside caliper is able to measure
sizes from 0-150 mm.
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Open out the jaws of the calipers until they pass clearly
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over the diameter to be measured. The work must be
stationary when measuring the sizes. (Fig 1)
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In the case of spring outside calipers, adjust the screw

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Place one point of the leg over the workpiece and get the nut so that the adjustment of the caliper just slips from
sense of feel of the other point of the leg. the external diameter of the workpiece to give the right
sense of feel.
If there is clearance on the other point of the leg, gently
tap the back of one leg of the firm joint calipers so that it When you have adjusted the outside caliper for the correct
just slips from the external diameter of the workpiece to 'feel' transfer the measurement to a steel rule or any other
give the right sense of `feel'. (Fig 2) precision measuring instrument as the case may be.
Keep the graduated steel rule on a flat surface and hold
the point of one leg firmly against the rule end. (Fig 4)

The point of one leg must be placed over the graduation In the case of precision measurements, transfer the
so that the point of the other leg is parallel with the edge of measurements over an inside micrometer or vernier caliper.
the steel rule. This measurement will give an accuracy of ± 0.01 or ±
0.02 mm. Here, the sense of feel of the user is very
Record the reading to an accuracy of ± 0.5 mm.
important in deciding the reading.
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Fitter - Turning
Holding job in three jaw chuck

• hold the job in three jaw chuck.
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101
Job Sequence
• Check the raw material size. • Keep the job in the chuck with overhang of 75 mm
• Open the jaws by chuck key • Tighten the jaws as required
• Open the jaws approximately more than job diameter • Check the trueness of the job
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Fitter - Turning
Perform the facing, plain turn, step turn, parting, deburr, chamfer corner,
round the ends, and use form tools
• hold the work in three jaw chuck
• face the end and plain turning
• step turn job ± 0.1 using power feed and a knife tool
• form turning using form tool
• parting off using parting tool
• grind parting tool and make under cut to the required size.
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103
Job Sequence
• Check the raw material for its size. • Reverse and hold the job at ∅ 30mm x width 32mm
inside the three jaw chuck keeping about 40mm length
• Hold the job in a 3 jaw chuck keeping about 75mm
outside the chuck and true the job.
outside the chuck.
• Turn ∅ 45mm x 40mm length.
• Set the tool to the correct centre height.
• Set the 2mm width parting tool to the correct centre
• Select and set the correct spindle R.P.M.
height
• Face one side first and turn the the outer diameter to
• Part the job using plunge cut method at ∅ 45 mm x
∅ 45mm for the maximum possible length.
width 8mm from the end face.
• Turn ∅ 30 mm x 32 mm length as shown in job drawing.
• Face the other end to a total length of 92mm.
• Turn ∅ 25 mm x 30 mm length.
• Set the chamfering tool to the correct centre height.
• Set the under cut tool, radius tool, to the correct centre
• Chamfer the ∅ 45mm corner to 3x45°.
height and hold it rigidly.
• Remove the sharp edge.
• Form a square groove 2 mm depth x 2 mm width at 30
mm and 62mm from the end face. • Check the dimensions.
• Form a radius 3 mm at ∅ 25mm x width 30 mm at the
end face.
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Skill Sequence
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Turning steps of different diameters

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• turn steps of different diameters for definite length on a shaft.
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When the width of step to be turned is more than the width Withdraw the tool from work and make the cutting edge
of the tool, it is turned by using a R.H. knife-edge tool. contact the face of the work to set the top slide graduated
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collar to zero with a backlash eliminated. (Fig.2)

Hold the previously turned shaft in three jaw chuck and true
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it at both ends (near the chuck and overhanging end).

Hold the RH Knife-edge tool in the tool post with its cutting
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edge at centre height and at right angle.

Set the machine to 300 r.p.m.
Start the machine and touch the tool tip on the surface of
work to set the cross-slide graduated collar to zero with the
backlash eliminated. (Fig.1)
Position the tool tip near the edge of the work. (Fig.3)
Give a depth of cut to turn steps progressively. (Fig.4)
Advance the tool axially to the required length by rotating

the top slide hand wheel.
(The rotation of the top slide hand wheel should be
continuous and uniform till the required length is reached).
Restrict the depth of cut to a maximum of 3 mm for each
cut.

Repeat the depth of cuts till the required diameter is
reached.
Keep the carriage in the locked position.
Corner forming tool

• grind the corner forming tool.
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Procedure for grinding corner forming tool (for external
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operation).
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Set the pedestal grinder for tool grinding.
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Wear goggles.
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Dress rough wheel, grind the tool approximately to a depth

of 10.00 mm, maintaining a wall thickness of 3 to 4 mm.
(Fig 1)
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Prepare a template out of M.S. sheet to check positional

accuracy. (Fig.2)
Now dress smoother wheel to form 2R at the corner.
Carborundum dresser is used to form corner radius.
Check the dressed wheel with template.
Grind 4°- 6° front clearance angle at the front and 3°- 4° side
clearance. (Fig.3)
Remove the step and form 2R and check with template.
Deburr with oil stone.
No rake angle is given.

Parting off operation
• set the parting off tool in the machine to the correct centre height
• follow the correct procedure while parting off
• observe certain precautions while parting off.
Parting off operation

Parting off or cutting off is the operation of severing a
finished part from the rough or finished stock.
Setting of parting tool
Set the parting tool exactly on the centre with as little back
rake as possible. (Fig 1)
Move the carriage so that the right hand side of the blade
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is at the point where the work is to be cut off. (Fig 4)
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Adjust the parting off tool so that it extends one half the
diameter of the work plus about 3mm for clearance from the
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tool-holder (Fig 2)
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Start the lathe and feed the tool steadily into the work using
the cross-slide handle.
Continue to feed the tool into the work until the part is
severed.
Precautions
The work should protrude from the chuck jaws, sufficiently
If the cutting tool is too high, it will not cut enough to permit the cut to be made as close as possible
through the work piece. If it is too low, the work to the chuck jaws.
may be bent and the cutting tool damaged. The work must always be held securely in a chuck or a
collet.
Procedure
If the workpiece is held between centres, it
Select the correct type of tool for a specified job. may bend or break and fly out of the lathe
Hold the work with the minimum overhang in a chuck. during parting off. (Fig 5)
Set the tool square with the work so that it does not rub
against the sides of the groove, as it is fed into the work
(Fig 3)
Set the spindle speed to half the speed for turning.

A work having more than one diameter should be gripped
on the large diameter while parting.
Intermittent feed tends to dull the tool’s cutting

edge.
Heavy feed causes jamming and tool breakage.

Use sufficient coolant on steel. Brass and cast iron should
be cut off dry.
Make sure the saddle is locked during the entire operation.
Reduce the rate of feed, when the work is almost cut off.
While parting off long work, it should be supported with the
Use a right hand offset tool-holder (Fig 6) tailstock centre.
If the machine is in good condition, the automatic cross
feed may be used.
When the tool has penetrated to about the depth of its
width, withdraw it and move it sideways with the compound
slide and feed again.
The above operation should be repeated frequently to
minimise the tendency of the tool to dig in and cause
trouble.
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When the parting off operation is almost completed, hold
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the workpiece by hand to prevent it from falling, so that
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Fitter - Turning
Shoulder turn : Square , filleted, beveled under cut shoulder, turning-filleted

under cut, square beveled
• set and true the job in a 3-jaw chuck
• face, plain and step turn the work by hand tool to an accuracy of ± 0.1 mm
• form square filleted under cut
• set and true the job to the run out accuracy of 0.1 mm
• turn square filleted shoulder
• turn bevel shoulder.
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108
Job Sequence
• Check the raw material size. • Reverse the job and hold it on the finished surface.
• Hold the job in three jaw chuck with minimum overhang. • Face the job to 108 mm length.
• Set the R.H. facing tool rigidly to the correct centre • Check the length with a vernier caliper.
height with a minimum overhang. • Turn the job to ∅ 23 mm to the 16 mm length.
• Set the machine to the predetermined R.P.M. • Step turn ∅ 15 mm to a length of 26.5 mm.
• Lock the carriage and face one end. • Bevel the ∅ 23 mm step to an angle of 4x45°.
• Set the R.H. turning tool in the tool post rigidly. • Turn ∅ 10 mm x 10 mm length
• Turn the job to ∅ 28 mm to the maximum possible • Chamfer the ∅ 10 mm step to an angle of 2X30°
length. • Remove burrs from the job.
• Step turn ∅ 15 mm to a length of 19.5 mm.
• Check the angle with a vernier bevel protractor.
• Check the dimensions with a vernier caliper. • Check the dimensions with a vernier caliper.
• Do filleted under cut R1.5x1.5 depth
• Make under cut of 4mm with and 4mm depth.
Skill Sequence
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Form an undercut shoulder at the junction of two diameters
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• set the undercutting tool in the tool post
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• set the tool at the required position

• perform undercut operations
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• check the undercut width and depth with a vernier caliper.
The end of a section to be threaded is mostly undercut to

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provide a channel into which the threading tool may run. It

allows the mating part to sit squarely against it. When the
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diameter is to be finished to size by grinding, a channel is

generally cut against the shoulder to provide a clearance for
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the grinding wheel, thus ensuring a square corner.

To form an undercut shoulder at the junction, the following
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procedure is to be followed.
Select a suitable tool bit or grind one to the shape and size
required.
Set correct spindle speed, and start the machine.
Rotate the top slide handle until the tool marks the shoulder
Rotate the carriage handle until the tool almost touches the lightly. (Fig 3)
face of the work. (Fig.1)
Lock the saddle in this position.

Note the reading on the graduated collar of the top slide
Rotate the cross-slide handle and touch the work surface
feed screw, and set the reading to zero.
lightly with the front cutting edge of the tool. Set the cross-
slide graduated collar to zero. (Fig.2)

Apply cutting fluid
Feed the tool slowly and evenly into the work to the required
depth using cross-slide handle (Fig 4)
Stop the lathe and check the undercut for its dimensions.
Remove sharp corners, if any.
Machining various shoulders

• machining various shoulders.
Machining a square shoulder Make sure that the tool bit is set up with the point close to
Face the end of the work to provide a reference surface the work, and with a slight space along the side cutting
point from which to take measurements. edge.
Lay out the position of the shoulder by one of the following Apply chalk or lay out dye to the small diameter, as close
methods. to the shoulder as possible.
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Cut a light groove with the point of a sharp tool bit around Before starting the lathe, the tool bit should be brought
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the circumference of the work to mark the required length. fairly close to the diameter, by using a piece of paper or
(Fig 1) thin stock between the tool bit point and the work diameter.
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Start the lathe and bring the facing tool in until it just
removes the chalk or the layout dye.
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Note the reading on the graduated collar of the cross-slide

screw.
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Bring the tool bit towards the shoulder with the carriage
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hand wheel until a cut is started.

Face the shoulder by turning the cross-slide handle anti-
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clockwise, thus cutting from the centre to the outside.

For successive cuts, return the cross-slide screw to the
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same graduated collar setting. Repeat the above procedure

until the shoulder is machined to the correct length.
Machining a bevelled shoulder (Fig 3)
Rough and finish turn the diameter to within about 1 mm
of the required length. Lay out the position of the shoulder along the length of the
workpiece, and set the tool as shown in Fig 3.
Mount a facing tool bit in the tool-holder and set it to centre.
(Fig 2)

Rough and finish turn the small diameter to size.
Mount a side cutting tool in the tool-holder and set it to
centre.
Apply chalk or layout dye to the small diameter as close
as possible to the shoulder location.
Bring the point of the tool bit in until it just removes the
chalk or layout dye.
Turn the carriage hand wheel by hand to feed the cutting
tool slowly into the shoulder.
Apply a cutting fluid to assist the cutting action and to
produce a good surface finish.
Machine the bevelled shoulder until it is to the required Apply a layout dye or chalk to the small diameter as close
size. as possible to the shoulder location.
If the size of the shoulder is large, and chatter occurs Set the lathe spindle speed to approximately one half of
when cutting with the side of the tool bit, it may be the turning speed.
necessary to cut the bevelled shoulder using the compound
rest. Start the lathe and bring the tool bit in until it just removes
the layout dye or chalk.
Set the compound rest to the desired angle. (Fig 4)
Note the reading on the graduated collar of the cross-slide
Adjust the tool bit so that only the point will cut. screw.
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Apply a cutting fluid to assist cutting action. Progressively Retract the cutting tool by turning the cross-slide handle
machine the bevel. Always cut outwards and start each
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cut near the outermost edge of the face of the shoulder.
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Be careful not to damage the small diameter when preparing Turn the cross-slide handle clockwise until it is within
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to make each new cut. At the start of the final cut, bring approximately 1 mm of the original collar setting. The point
the point of the tool bit in, until it just removes the chalk or of the round nose tool bit should now be about 1 mm away
from the work diameter. This prevents the cutting tool
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layout dye at the innermost edge of the original shoulder

face. from undercutting while roughing out the filleted corner.
Turn the carriage hand wheel slowly to start the radius
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tool cutting the filleted shoulder. If chattering occurs while

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machining the filleted corner, reduce the lathe speed and

apply a cutting fluid to improve the finish of the fillet.
(Fig 5)
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Continue turning the carriage hand wheel slowly and

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carefully until the length of the shoulder is correct.

When stopping the lathe to measure the shoulder distance,
do not move the cutting tool setting by withdrawing it from
the diameter. (Fig 6)
Machining a filleted shoulder (Fig 5)

Lay out or mark the location of the shoulder on the
workpiece.
When laying out for a filleted shoulder make allowance for
the radius to be cut. If a filleted shoulder has a 4 mm
radius and is 60 mm from the end of the workpiece, the
layout should be 56 mm from the end. This would leave
material for cutting the radius.
Mount a radius tool in the holder and set it to centre. Turn the carriage hand wheel to move the cutting tool away
Check the tool bit with a radius gauge to be sure that it from the shoulder slightly.
has the correct radius.
Turn the cross-slide handle anticlockwise about 1 mm Bring the point of the tool bit in until it just removes the
back to the original collar setting. chalk or layout dye on the face and set the top slide
graduated collar to zero.
Finish the filleted corner by carefully advancing the radius
tool bit with the carriage hand wheel. Apply a cutting fluid to assist the cutting action and produce
a good surface finish.
If the radius is too large for a form tool bit, or too much
chattering occurs, cut the fillet in steps, using the largest Retract the cutting tool by turning the cross-slide handle
radius tool that does not cause chattering. Check the anticlockwise.
accuracy of the fillet with a radius gauge. (Fig 7)
Repeat the above procedure until the undercut shoulder is
machined to the correct depth.
Bring the tool tip clear off the large diameter face and
advance the tool axially by 1 division of the top slide.
Feed the tool into the work from the edge of the larger
diameter face, till it just removes the chalk mark applied
on the small diameter.
Note the cross-slide graduated collar reading and advance
the tool into the work to the number of divisions required
according to the depth.
Ensure that the tool cutting edge is parallel to

the work axis.
Ensure that the carriage is locked during the
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undercutting operation.
Machining an undercut shoulder
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Apply a cutting fluid to assist the cutting action and to
Lay out the position of the undercut shoulder along the
produce a good surface finish.
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length of the workpiece.

Retract the cutting tool by turning the cross-slide handle
anticlockwise.
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Mount the undercut tool in the tool-holder and set it to the

Repeat the above procedure until the undercut shoulder is
centre.
machined to the correct depth.
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Apply chalk or layout dye to the small diameter as close

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as possible to the undercut shoulder location and also on

the face of the larger diameter.
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Set the lathe spindle to approximately one half of the turning

speed.
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Fitter - Turning
Sharpening of - single point tools

• grind side cutting tool for machining steel.
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113
Job Sequence
• Before starting wear safety goggles. • Grind the top of the tool for a side rake angle of 12o to
• Check the gap between the wheel and the tool rest, 15o.
and maintain the gap 2 to 3 mm. • Finish grind all angles and clearances - on a smooth
Damages or any corrections needed should wheel.
be brought to the notice of the instructor. • Grind a nose radius of approximately 0.5 mm R.
• Hold the blank against the wheel to grind the end The ground surfaces should be without steps
cutting edge angle 20o to 25o and the front clearance and should have a uniform smooth finish.
angle between 6o to 8o - simultaneously.
• Grind the side of the tool - for giving 6o to 8o side
clearance. The side length should be equal to the width
of the tool blank.
Skill Sequence
Grinding a side cutting tool for machining steel

• grind a right hand side cutting tool to machine steel.
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The side cutting tool to be used on steel is illustrated in
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Figure 1. The right hand portion illustrates the tool blank
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in dotted lines before grinding, and the ground tool by
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thick lines. (Fig 1)
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The side cutting edge is in line with the blank edge and
the end cutting edge is inclined at an angle of 25°. The
side rake angle is 14°. The front and side clearances are
ground 6°. The length of the side cutting edge is maintained
equal to the size of the square cross-section of the tool
blank, i.e. 12 mm. Fig 2 shows the shaded portion to be
removed by grinding the tool blank to get the ground tool.
The procedure in sequence is as follows.
Grind the side rake angle of 14°. Angle ‘r’. (Fig 4)
Grind the end cutting edge angle 25°. Angle ‘xn’ (Fig 3)

Grind the front clearance angle of 6°. Angle ∅ (Fig 6)
Grind the side clearance angle of 6°. Angle ∅ (Fig 5)

Grind and provide a nose radius of R 0.4 to R 0.6 mm at
the point of tool. Grind a flat for a short length of 0.2 to 0.3
mm as shown in Fig 7. For the sake of clarity the figure is
magnified.
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Fitter - Turning
Cut grooves - square, round ‘V’ groove

• hold the job in lathe chuck
• set the turning tool
• set the machine spindle speed
• parallel turn the work piece by hand feed
• set the tool for groove turning -’V’ tool, radius tool and square tool.
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Job Sequence
• Check the raw material for its size. 30 mm from the end face.
• Hold the job in 3 jaw chuck keeping about 50mm • From a radius groove 2.5 mm depth x 5mm width at 18
outside the chuck mm from the end face.
• Set the tool to the correct centre height. • Plunge the ‘V’ groove tool to form a ‘V’ groove 5mm
width at 6mm from the end face.
• Select and set the correct spindle R.P.M.
• Reverse and hold the job.
• Face one side first and turn the outer diameter to ∅
42mm for the maximum possible length. • Face the other end to a total length of 75mm.
• Turn ∅ 30 mm x 35 mm length. • Turn ∅ 42 mm x 40 mm length
• Set the under cut tool, radius tool, ‘V’ groove tool to • Remove the sharp edge
the correct centre height and hold it rigidly.
• Check the dimensions.
• From a square groove 2.5 mm depth x 5mm width at
Skill Sequence
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• grind 60° ‘V’ tool.
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1 Grind the tool to the given angle of 60°
• ish
Mount the tool and set centre height properly
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• Set the speed, lock the carriage

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• Move the cross slide and plunge the tool to the

required size.
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• Check the depth of the ‘V’ groove. (Fig 1)

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2 Grind the tool 4 mm radius

• Mount the tool and set centre height properly
• Set the speed, lock the carriage
required size. (Fig 2)
3 Grind the tool to thte required width of 4 mm
• Mount the tool and set centre height properly.
• Set the speed, lock the carriage.

required size. (Fig 3)

Fitter - Turning
Make a mandrel - turn diameter to sizes

• mount the driving plate on spindle nose of lathe spindle
• protect the centre hole by crowning
• turn the mandrel with an accuracy of ±0.1 mm
• turn with carbide tipped tool.
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Job Sequence
• Check the size of the raw material. • Set the spindle r.p.m. and rough turn diameter to
• Hold the job in a 4 jaw chuck and true it. 24.16 mm. to maximum possible length
• Set the spindle R.P.M. and face one end. • Turn step ∅ 21 for 18 mm length and chamfer
2 x 45°.
• Centre drill with the help of the tailstock and drill
chuck. • Reverse the job and turn ∅ 21 mm for 18 mm length
and chamfer 2x45°.
• Reverse and true the job.
• Set the form tool to 60° and turn taper on step dia. as
• Face to length 160 mm and centre drill.
shown in the sketch.
• Crown centre holes using the special centre drill.
• Check the size with an outside micrometer.
• Dismount the 4 jaw chuck from the lathe spindle and
• Set the taper turning attachment for the small taper.
mount the driving plate on the spindle nose.
• Adjust in such a way that ∅ 24 mm diameter at the
• Clamp the job on a suitable lathe carrier and support
the work between centres. centre of the mandrel is achieved.
Skill Sequence
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Turning work held on a plain mandrel
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• mount the work on a mandrel
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• machine the work held on a mandrel.
It may sometimes be necessary to machine external

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If an arbor press is available, place the work on the arbor

surfaces of a cylindrical work accurately in relation to a press table, preferably with the machined surface
hole that has been previously bored in the centre of the downwards. (Fig 1)
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work. In such cases the work is mounted on a mandrel

and machined.
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Work has to be mounted on a mandrel before holding on a

lathe for machining. The following sequence is to be
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followed for mounting work on a mandrel.

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Select the correct size of the mandrel to suit the hole of

the workpiece.
Clean and apply a light film of oil or soft grease on the
diameter of the mandrel.
Remove the burrs from the edge of the hole in the
workpiece.
Clean and lubricate the hole in the workpiece to prevent
seizing or scoring when the mandrel is pressed into or out
of the work.
Insert the small end of the mandrel squarely into the hole
by hand. It should enter the hole approximately about 25
mm and should square itself.
Note: The larger end of the mandrel has the Press the mandrel firmly, but not too tightly, into the
size stamped on it. workpiece.
If the mandrel is forced into the work tightly, it may distort,
damage the bore of the workpiece, and sometimes break
the workpiece.

If an arbor press is not available, use a lead hammer to Avoid overhang of the tailstock spindle.
drive the mandrel into the hole by light hammering. To prevent the work getting forced off from the mandrel,
(Fig 2) avoid taking cuts from the larger diameter end towards
the smaller.
Very light cuts should only be taken on a work of a larger
diameter mounted on a small mandrel.
If possible, drive the workpiece directly from the drive plate
by means of a suitable stud. This will prevent the work
from slipping. (Fig 3)
Note: The workpiece is pressed on a solid plain

mandrel, and is held in position approximately
at the centre of the mandrel length only by
friction. Take all cuts towards the large
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diameter end of the mandrel and avoid taking
heavy cuts.
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Mount a suitable lathe carrier on the large diameter end.
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Check for the true running of the live centre.

Check the alignment of the live centre and the dead centre
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of the lathe with a test bar and dial indicator.

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Clean the lathe centres and the centre holes of the mandrel
thoroughly.
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Mount a catch plate or driving plate to the spindle nose.

Mount the mandrel with the workpiece in between centres,
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and carefully adjust the force on the centres.

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Fitter - Turning
Knurl the job

• hold the job in lathe chuck
• set a knurling tool in the tool post
• knurl on the cylindrical surface.
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121
Job Sequence
• Check the raw material size • Turn the job ∅ 25 x 50 with a side knife tool. (Use a
vernier caliper for measuring dimensions.)
• Hold the material securely in a 3 jaw chuck projecting
50 mm outside the chuck. • Chamfer to 2x45° at the end with a 45° chamfering tool.
• Face the one end. • Deburr all sharp edges.
• Turn the job to ∅ 40-0.2 for more than the required for Remember
knurling • Avoid overhanging of the tool.
• Hold the diamond knurling tool securely and set it to the
• Use aluminium pieces for packing, to avoid marks on
centre height.
the knurled surface.
• Select the suitable speed for the knurling operation.
Safety precautions
• Knurl the surface till a diamond shape is formed
• Never operate a lever when the machine is in motion.
• Chamfer 2x45° at the end.
• Do not keep any tools on the moving parts of the
• Reverse and hold the job in the chuck and true the job. machine.
• Face the end and maintain the length of 80 mm. • Use a suitable coolant.
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Skill Sequence
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Knurling on lathe
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Objectives: This shall help to you

• prepare the work for knurling
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• set the speed for knurling

• set the knurling tool in the tool post
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• knurl the job using the required grade of knurl.

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For better grip and for a good appearance on cylindrical Set the machine for a low speed, preferably 1/3 to 1/4 of the
surfaces, a portion of the component is knurled. The turning speed. Mark off the length to be knurled.
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procedure of knurling, in sequence, is as follows.

Adjust the knurling tool so that it is at right angles to the
Reduce the diameter of the portion to be knurled depending axis of the work; tighten it firmly. (Fig 2)
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upon the grade of knurl and material of the job. Reduce 0.1
mm for fine knurling, 0.2 mm for medium knurling and 0.3
mm for coarse knurling approximately.
Support the job knurling tool in the post with the centre of
the floating head at the same height as the lathe centre
point. (Fig 1)
Feed the knurl and make the pair of knurls to contact the
work periphery by the cross-slide hand wheel.
Move the carriage until about the face of the knurling roll
overlaps the end of the workpiece which helps to produce
a true pattern.(Fig 3)

Stop the lathe and reset the knurling tool, if necessary.
Feeding the knurl into the workpiece, before it
is rotated, may damage the knurl.
Move the knurling tool longitudinally with a uniform
movement by the carriage hand wheel up to the required
length of the work to be knurled.
Give the depth by the cross-slide without drawing the tool
back. Feed the knurling tool to the other end.
Until the correct pattern is obtained, do not
withdraw the knurling tool back.
Ample coolant is to be applied to the workpiece being
knurled. This washes away any metal particles, and
provides lubrication for the knurling rolls.
Use a fine feed for knurling hard metals and a
Start the lathe and feed the knurling tool into the work by
coarse feed for knurling soft metals.
the cross-slide.
Clean the knurl with a brush for subsequent cuts.
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Fitter - Turning
Bore holes - spot face, pilot drill, enlarge hole using boring tools
• drill through hole
• bore a hole to an accuracy of ± 0.04 mm with boring tool
• measure the bore by using a vernier caliper
• re-shapen a twist drill
• check the twist drill for its performance
• spot face the end of bored hole.
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Job Sequence
• Check the raw material for its size. • Use coolant while drilling and advance the drill slowly.
• Hold the job in a 4 jaw chuck and true it, keeping about • Enlarge ∅12 mm hole to ∅20 mm hole by drilling at a
45mm outside the chuck. reduced spindle speed.
• Set the facing tool to the correct centre height. • Set the boring tool in the tool post to the centre height
and bore the drilled hole to ∅24.7 mm through.
• Select and set the correct spindle speed, for facing.
• Check the bore with vernier caliper.
• Face one side first, and turn the outer diameter to ∅40
mm for the maximum possible length. • Make spot face 4x4 mm by boring tool
• Centre drill. • After completion of drilling throughout the job reverse
and true the job; face to the required length as per
• Select the required size of drills including the pilot drill. drawing, and turn outer dia ∅40mm.
• Hold the drill in the tailstock spindle with the help of • Make spot face by boring tool 4x4 mm
suitable sleeves after cleaning.
Safety precautions
• Select the spindle speed for drilling the pilot hole of
12mm dia. • Select proper spindle speeds as per size and operation.
• Bring the tailstock to a convenient position for drilling, • Use pilot drill while drilling more than 20mm drill size.
and lock the tailstock on the bed. • Feed the drill slowly while drilling.
• Run the lathe and advance the drill, so that it does the • Use coolant while drilling.
drilling opeartion on the job held in the chuck.
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Skill Sequence
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Boring a drilled hole

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• set the boring tool in the tool post
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• bore the drilled hole to the required size

• check the hole with the help of a vernier caliper.
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Boring is an internal operation of enlarging a hole with the Use the largest diameter boring tool which can be
help of a single point cutting tool. (Fig.1) accommodated in the drilled hole. (Approximately 2/3rd
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Set the cutting edge of the cutting tool just slightly above
the centre line, since there is tendency for the tool to spring
downwards when cutting.
Choose a proper feed for rough boring.
The speed for boring is the same as that for
turning and is calculated for the diameter of the
bore.
Start the machine and turn the cross-slide handle
anticlockwise until the cutting tool touches the inside
surface of the hole. (Fig.2)
To bore the hole the following procedure is to be followed.
Mount the workpiece in a four jaw chuck. True the face of
the work and the outer diameter.
Set the lathe to the proper spindle speed for boring.
Mount the boring tool on the tool post of the compound rest.
Fix the boring tool, level and parallel to the centre line of the
lathe.
Grip the boring tool as short as possible to
reduce chatter.

Take a light trail cut about 0.2 mm deep and about 8 mm
long at the right hand end of the work. (Fig.3)
Keep the machine and move the carriage to the right until
the boring tool clears the hole. (Fig.6)
Stop the machine and measure the diameter using a

telescopic gauge or inside caliper. (Fig.4)
Set a fine feed of about 0.1 mm for the finish cut.
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Set the cutting tool for the required depth to get the finished
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Calculate the amount of material to be removed from the
Use the cross-slide graduated collar.
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hole for the roughing cut. Finish the boring operation and measure with a vernier
caliper.
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Leave about 0.5 mm undersize for a finish cut.

To avoid bell mouth, repeat the same cut.
Take a roughing cut for the required length. (Fig.5)
Several cuts taken without adjusting the depth of cut would
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Remove the sharp corners.

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Inside calliper & outside micrometer used for bore measurement

• take the measurement of a bored hole with an inside caliper, transfer it to an outside micrometer and read
the measurement.
Bores are checked for their dimensional accuracy by Select the inside caliper according to the size of the bore
using: to be measured.
- Inside micrometers. Select an outside micrometer of suitable range for the size
of the hole.
- Universal vernier calipers.
Open the legs of the inside caliper approximately permitting
- Inside calipers and outside micrometers (transfer
its entrance into the hole.
measurement).
Position one leg in contact with the bottom of the bore.
- Telescopic gauges and outside micrometers (transfer
measurement). Keeping this as the fulcrum, oscillate the other leg in the
bore.
The first two methods give direct reading whereas the 3rd
and 4th are by transfer measurement. Adjust the distance between the legs by gentle tapping to
increase or to decrease so as to enable the leg to enter.
For checking the bore diameters using inside calipers and
outside micrometers the following sequence is to be
followed.

Rock the inside caliper with respect to the axis of the work Oscillate the other leg and rotate the thimble of the outside
so as to make the leg of the inside caliper contact the bore micrometer to contact the tip of the oscillating leg of the
top surface. (Fig 1) inside caliper. (Fig.2)
If the ‘feel’ is hard, reduce the distance between

the leg tips and if the feel is less or if there is no
feel, increase the distance between the leg tips
slightly.
Ensure you get the same 'feel' as before.

Check once again and repeat till you get the correct feel.
Ensure that the position of the legs is not disturbed, once Note the readings on the barrel and thimble of the outside
the correct feel is obtained. micrometer, and determine the size of the measurement.
Hold the outside micrometer in one hand, and the spindle
The accuracy depends on the skill. Practice to
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away from the anvil face, a little more than the distance
get the correct feel for the measurement.
between the two legs of the inside caliper.
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Hold the inside caliper with the other hand, contacting the
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tip of one leg with the anvil face of the micrometer.
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Fitter - Turning
Make a bush step bore-cut recess, turn hole diameter to sizes

• grind recessing tools
• perform step boring
• form an internal recess
• check the diameter of the recess by a transfer caliper.
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128
Job Sequence
• Hold the job in a 4 jaw chuck and true. • Perform R3 on a ∅ 45 at one edge, with a 3R radius tool
• Face the end and centre drill. • Deburr all the sharp edges and check with the precision
instruments.
• Drill ∅10 mm hole through and enlarge to ∅ 14 mm by
drilling Points to remember
• Bore through hole to ∅ 15 mm • Hand feed should be uniform to obtain good surface
finish; work with a round nose tool.
• Finish turn the outer dia.to size ∅ 45 mm for possible
lenght • Set the radius tool properly to avoid chattering marks.
• Reverse the job, hold on ∅ 45 mm and true • Limit the speed for internal recessing i.e, 1/3rd of the
drilling R.P.M.
• Face to maintain the total length of 40 mm.
• Lock the carriage while recessing operation is done, to
• Bore ∅ 28 mm to 33 mm length, set the recessing tool avoid vibration.
• Form recess 4 mm width as per drawing and R2 ∅ 35 • Use a transfer caliper to measure ∅ 35 mm.
mm.
• Check the radius with a radius gauge.
Skill Sequence
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Internal recessing to a size broader than the width of the tool
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Objectives : This shall help you to
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• grind an internal recessing tool maintaining a definite width of 4 mm

• cut an internal recess of a given diameter for the required width.
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At times, it may be necessary to form the recess for A recessing tool is to be ground to a definite width ‘w’, say
sufficient length for the same diameter. This is necessary 4 mm. The relief given is 2° on both sides. The front
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to clearance is about 12° and the front edge is ground to 45°

of the secondary clearance, avoiding the bottom of the
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- Reduce the weight of the bush

tool fouling with the bore diameter. The front cutting edge,
- Have contact surfaces with the shaft only at both ends ‘with a primary clearance of 12°, is kept to about 1/5th of
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of the bush the height ‘h’ in order to have a maximum portion, ground
- Have parallelism in the bore diameter at both ends. to the secondary clearance. The cutting edge is ground
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(Fig 1) parallel to the axis. A small back rake of about 6° is ground

on top of the cutting edge.(Figs 2 and 3)

Lock the carriage and withdraw the tool from the face, and
touch the bore diameter with the front cutting edge of the
tool. (Fig 6)
The procedure in sequence is as follows. Set the cross-feed graduated collar to zero with the
backlash eliminated.
Hold and clamp the tool in the tool post to have the cutting
edge to exact centre height and parallel to the axis of the Release the cutting edge from the bore diameter, and
work. Use the tool setting gauge as shown in Fig 4. position the left side of the cutting edge of the tool at the
start of the bore.
The top slide graduated collar reads the

previously marked zero setting with the
backlash eliminated.
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cutting edge + the distance from the front face to the
starting position of the recess. (Fig 7)
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Keep a minimum overhang of the tool.

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Touch the leftside of the cutting edge so as to just contact

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the work face. (Fig 5)

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Example
In the example shown, it is equal to 4 mm +25
mm = 29mm. (Tool cutting edge width ground
for 4 mm width).
Rotate the cross-slide hand wheel in the anticlockwise
direction till the tool cutting edge touches the bore.
Ensure the graduated collar zero is in line with
the fixed mark in this position.
Continue rotating the cross-slide hand wheel in the
Set the top slide graduated collar to zero with the backlash
anticlockwise direction to make the tool advance deep,and
eliminated.
form the recess.
Set the machine to about 250 r.p.m.
Continuous, uniform, and slow feeding is
necessary.
The spindle speed depends upon the material
and diameter of the bush. In the example given, the advancement of the tool is 10mm.
Note the cross-feed graduated collar reading in this
position.

Rotate the cross-slide hand wheel in the clockwise
direction till the tool cutting edge is released from the
recess.
Advance the tool axially by the top slide movement for
about 3/4th width of the tool. (Fig 8)
Rotate the cross-slide hand wheel till the tool tip reaches
the same depth (10 mm in the example).
Repeat the steps till the required length of the recess
(50mm) is reached.
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Rotate the top slide graduated collar in the anticlockwise
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direction, continuously and uniformly to clean the recess
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till the right hand end of the cutting edge just touches the
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face at the start of the recess.
Withdraw the tool from the recess and the bore.
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Check the diameter of the recess with the indicating

caliper. (Fig 9)
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Clamp the internal chamfering tool and chamfer the edges

of the recess to remove the burrs. (Fig 10)
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Form a recess
• set the recessing tool in the tool post
• set the tool at the required position
• perform different types of recesses
• check the recess using an inside caliper.
Recessing Calculate the distance from the face to the edge of the
groove farthest from the end face.
Recessing is the process of cutting an annular channel
inside the bored hole. Turn the top slide handle back to ensure that the slide can
move the required distance.
To perform recessing, the following procedure is to be
followed. Touch the tool edge to the face of the workpiece using the
top slide handle.
Select an internal recessing tool of the correct width.
The tool may be made to contact the feeler gauge held
Check that the tool or boring bar will clear the work of the
between the edge of the tool and the face of the workpiece.
bore.
Set the compound slide graduated collar to zero.
Mount the tool on the tool post.
Align the face of the tool to the wall of the bore.
Turn the cross-slide handle so that the front of the tool Note the cross-feed graduated collar reading.
just clears the wall of the bore.
Rotate the cross-slide hand wheel in the same direction
Turn the top slide handle to position the tool at the to make the tool to remove the metal from the bore to form
calculated distance into the bore. the recess.
If a feeler gauge has been used in the above Feed the tool slowly and continuously till the calculated
procedure, allow for the thickness of the gauge division of the cross-slide reaches the zero mark.
when calculating the distance to move the top
Reverse the direction of rotation of the cross-slide hand
slide.
wheel and make the cutting edge clear the diameter of
Turn the cross-slide hand wheel in an anticlockwise the bore.
direction to advance the tool and touch the wall of the
Retreat the tool by moving the saddle towards the tailstock.
bore.
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Fitter - Turning
Turn taper (internal and external)

• hold the work in between centres
• knurl the surface
• produce taper bore by compound slide
• set the compound rest to the specified angle
• turn the external taper by the compound rest method
• check the taper with a vernier bevel protector.
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133
Job Sequence
TASK 1: Taper turning internal
• Hold the knurled job and face the ends to maintain a
• Hold the job in a 4 jaw chuck and true it.
length of 37.5 mm.
• Set the tool to correct centre height.
• Chamfer the end to 2x45°.
• Face one end of the job.
• Set the compound rest to the 5° 45’ with the help of a
• Turn ∅ 44.75 mm to a length of 45 mm. vernier bevel protractor.
• Set the knurling tool (diamond cut) to correct centre • Set the boring tool, to the correct centre height.
height.
• Turn taper as per drawing.
• Knurl the job to a length of 40 mm.
• Match the taper.
• Drill pilot hole ∅ 16 mm by drilling
Safety precautions
• Chamfer 2x45°.
• Remove all sharp comers.
• Set the parting tool to centre height and cut off to a
• Use slow speed while knurling.
length of 40 mm.
• Use plenty of coolant while drilling, taper turning and
knurling.
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TASK 2: Taper turning external
• Check the raw material size.
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the formula
• Hold the job in between centres.
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• Swivel the compound rest slide to the above angle using
• Turn the step Ø12 x 15 mm long at the taper end. a vernier bevel protractor.
• Turn MT4 taper by attachment method
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• Turn the taper by using the top slide feed and maintain
• Reverse and refix between centres. the major dia. to 31.26 mm. minor dia to 25.90 mm
and length to 103 mm.
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• Turn the step Ø12 x 15 mm long from the other end of

job. • Check the size of the job with a vernier bevel protractor
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and vernier caliper.

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Skill Sequence
Checking a tapered bore using a taper limit plug gauges

Objective: This shall help to you
• check the internal taper with taper plug gauge.
A taper limit plug gauge ensures the accuracy of the angle Assemble the taper plug gauge inside the tapered bore
and the linear dimensions of the taper bore. (Fig 1) carefully with sufficient force to ensure positive contact
between the gauge and the bore, and give one quarter twist
to the plug gauge.
Carefully remove the taper limit plug gauge and check if the
prussion blue is rubbed off uniformly, atleast to about 75%
of its area. This ensures the accuracy of the angle required.
Then once again insert the taper plug gauge inside the
taper bore and check, if the big dia, end of the bore falls
within the ‘Go’ and ‘No-Go’ limits marked on the gauge, this
ensures the dimensional accuracy of this tapered bore.
(Fig 3)
Clean the tapered bore.
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Apply a thin layer of prussion blue on the traper limit plug
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gauge along its length. (Fig 2)
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Turning taper by compound slide swivelling

• turn the taper using a compund slide
• check the taper with a vernier bevel protractor.
One of the methods of turning taper is by swivelling the Ensure that equal pressure is exerted by the
compound slide and feeding the tool at an angle to the axis spanner for both the nuts.
of the work by hand feed. (Fig 1)
Fix the turning tool in the tool post to the correct centre
Set and true the job turned to the bigger diameter of taper. height.
Set the machine to the required rpm. Keep a minimum overhang of the tool.
Loosen the top slide clamping nuts. Set the top slide to the rearmost position.
Swivel the top slide to half the included angle of the taper Position the saddle such that the tool is able to cover the
as shown in Fig.2. full length of the taper to be turned.
Ensure that the top slide does not travel beyond the edge
of the base.

Lock the carriage in position.
Touch the tool to the work - surface during running and set
the cross-slide graduated collar to zero.
Bring the tool to clear off the work by the top slide hand
wheel movement.
Give a depth of cut by the cross-slide and feed the tool by
the top slide hand wheel till the tool clears from the work.
Feeding by the top slide must be uniform and

continuous.
Give successive cuts by the cross-slide and
feed the top slide each time.
Check the angle of the turned job with a vernier bevel

protractor.
Adjust the swivel if there is any difference.
Continue the taper turning and finish the taper.
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Compound rest setup for turning various angles
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Fitter - Turning
Turn taper pins

• set the tool in the tool post
• set the taper turning attachment to the required angle
• turn the job in diameter 1:50 taper ratio.
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138
Job Sequence
• Check the raw material size. • Turn the diameter taper ration of 1:50
• Set the job on a four jaw chuck. • Check the diameter of both end as ∅ 20 and ∅ 19
• True the job • Set the parting tool
• Turn the job ∅ 20 mm up to the length of 55 mm • Feed the cut and remove the length of 50 mm.
• Set the tapper turning attachment
Skill Sequence
Do not part off component before check the diameter of
both end and length of 50 mm. (Fig 1)
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Fitter - Turning
Turn standard tapers to suit with gauge

• set taper turning attachment to turn taper
• set the tool in the tool post
• turn standard taper MT3
• check the taper with gauge.
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140
Job Sequence
• Set the job in four jaw chuck projecting [(l1 - l2 + 10 • Chamfer the two ends of ∅ d2 to 1x45°.
mm)] outside the chuck. • Reverse the job and hold turned dia d2 by giving
• True it by universal surface gauge. aluminium/copper sheet as a packing.
• Set the carbide tip tool to the correct centre height for • True the job by using suface gauge.
facing with offset facing tool. • Face the end to maintain a length of l1 .
• Set offset side cutting tool for turning. • Turn dia d1 and check by using vernier micrometer.
• Set the spindle speed as per the cutting speed chart. • Set the taper turning attachment to turn a taper of
• Face the one end. 1°26’16”.
• Turn dia 15mm for a length equal to (l1 - l2). • Turn taper MT3 and check the dimensions as per the
drawing by using vernier micrometer and vernier bevel
• Form grooving, after leaving l3 from the end and maintain protractor.
dia d2.
• Check the taper with gauge.
Skill Sequence
Producing taper by using taper turning attachment

Objectives: this shall help you to
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• set the taper turning attachment to the required angle
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• produce taper by using a taper turning attachement.
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A taper turning attachment provides a quick and accurate Set the required r.p.m
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means of turning tapers.

Feed the cutting tool in until it is about 6 mm from work
The following procedure is to be followed during turning surface.
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taper using a taper turning attachment.

Remove the locking screws which connect the cross-slide
Check for backlash between the guide bar and the sliding and the cross -slide nut.
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block, and adjust, if necessary.

Use the blinding lever to connect the cross-slide extension
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Clean and oil the guide bar. and sliding block.

Loosen the locking screws, then swivel the guide bar to the Insert a suitable plug in the hole on the top of the cross slide
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required angle. to protect the cross-slide screw from dirt and chips.
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Tightern the locking screws. The compound slide must now be used to feed the cutting
tool into the work.
Adjust the base plate until the ends of the guide bar are
equidistant from the cross-slide extension. Move the carriage to the right until the cutting tool is 12 mm
away from the right hand end of the workpiece.
Set up the cutting tool on exact centre.
This removes any play in the moving parts of
Any error will result in an incorrect taper
the taper turning attachment.
Mount the workpiece on the chuck or between centres.
Switch on the lathe.
Adjust the carriage until the cutting tool is approximately
Take a light cut of about 2 mm long and check the end taper
opposite to the centre of the tapered section.
for size.
Lock the clamping bracket to the lathe bed to secure the
Set the depth of the roughing cut.
taper turning attachment in this position.
Machine the work as with plain turning.
When using a plain taper turning attachment,
follow the steps given below at this stage. Remove the play by moving the cutting tool 12 mm beyond
the right hand end of the work at the beginning of each cut.
Adjust the top slide so that it is parallel with the cross-slide,
i.e at 90° to the work. Check the taper for fit.
Set up the cutting tool for the correct position. Readjust the taper turning attachment, if necessary a light
cut and recheck the taper.
Wear safety goggles.
Finish the taper to size and fit it to the taper gauge.

Fitter - Turning
Practice threading using taps, dies on lathe by hand

• set the job in a three jaw chuck
• drill through hole
• cut internal thread in a lathe using tap and tap wrench
• set the pre machined round rod with three jaw chuck
• cut external thread in a lathe using die and die stock.
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142
Job Sequence
TASK 1:
• Check the raw material size. • Place the first tap taper lead in hole and support other
end with tail stock dead centre.
• Hold the job in a 3 jaw chuck
• Form thread by first tap, second tap and third tap one
• Centre drill and drill ∅ 8.2 mm for M10
by one by hand rotate clock wise slowly and half
• Chamfer the drilled hole on both sides. rotation to release chips till you get the full formation of
• Fix the tap wrench to the square end of first tap internal thread.
• Apply oil and clean burrs
• Check the thread hole by M10 bolt.
TASK 2:
• Check the raw material for its size. • Increase the depth of cut gradually and cut thread to
match M10 nut by adjusting the screws provided in
• Hold the job in a 3 jaw chuck
the die stock.
• Turn the job for blank size of ∅ 9.85 mm to 50 mm
• Check the thread with the matching round nut
length
(Task 1).
• Chamfer the end of the job.
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• Clean the threads without burrs.
• Hold the die parallel to job face.
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Rotate the die for a thread forward and for half thread
Note: The tap wrench and die stock handle must
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backward with appropriate push to cut thread and
be short enough to ensure to rotate on lathe
remove chips.
bed.
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Skill sequence
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• cut internal and external thread in lathe using tap and die.
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TASK 1: TASK 2:
Cutting internal thread using tap and tap wrench in lathe. Cutting external thread using die and die stock in lathe.
(Fig 1) (Fig 2)
Fig 2

Fitter - Turning
Make external ‘V’ thread

• hold the job in lathe machine
• turn and chamfer as per drawing
• grind threading tool to cut metric thread on lathe
• cut metric thread on lathe by single point tool
• check the metric thread using thread ring gauge.
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144
Job Sequence
• Check the raw material size. • Set the metric ‘V’ threading tool in the tool post and with
the help of centre gauge, set threading tool perpendicular
• Hold the job in the chuck with 40 mm overhang and true to the axis.
it.
• Set the machine for 2.5 mm pitch to cut right hand
• Face end and turn to ∅ 27 mm to maximum length thread.
possible.
• Set across slide graduation collar to size.
• Chamfer 1.5×45° at the end.
• Cut right hand metric ‘V’ thread, giving depth of cut by
• Reverse and hold the job in the chuck with 75 mm the cross slide for successive cuts.
overhang, face and centre drill.
• Withdraw the tool at the end of each cut by the cross
• Chamfer 1.5×45° at the end. slide. Again advance to zero before giving depth of cut
• Turn the job to ∅ 22 mm to length of 75 mm. by the cross slide.
• Chamfer 1 x 45° at the end. • Rough and finish the thread and check with a thread ring
gauge.
Skill Sequence
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Chamfering on lathe
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• chamfer the end to required size.
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Grind the tool to the given angle usually 45°.

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Mount the tool and set centre height properly.

Set the speed, lock the carriage.
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Move cross slide and plunge the tool to the required size.
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Check the length of chamfer by vernier caliper.

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If the protruding length is greater, support with

centre.
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Make sure the tool is perpendicular to the lathe

axis.
Grinding 60° threading tool

• grind 60° threading tool.
Set the pedestal grinder for tool grinding.

Remove excess material on right hand side of the tool to
length equal to thickness of tool and width being half of the
thickness of tool on rough grinding wheel. (Fig.1)

Hold the tool at an angle of 60° to the face of the wheel, grind Finish all slides by using smooth grinding wheel.
30° on left hand side of the tool. (Fig.2)
Do not Grind Rake Angle
Check the tool by centre gauge, there light should not pass
through gauge and cutting edge of the tool. (Fig.4)
Repeat the above procedure on the right side of the tool to

get an included angle of 60° on the tool. (Fig.3)
Cutting point is curved to 0.14 × pitch by carefully grinding

in smooth wheel.
Finally Lap the tool by applying oil stone on cutting edges.
Safety precautions
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Ensure grinding wheels are properly guarded.
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Keep 2 mm gap between tool rest and grinding wheel face.
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Ensure cutting edge is visible to the operator while grinding.
Do not give too much pressure on the wheel face.
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Grind 6° to 8° side clearance angle on each side of the tool. Frequently cool the tool in coolant.
Grind 4° to 6° front clearance angle.
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Cutting ‘V’ thread by plunge cut method

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• cut ‘V’ thread using a single point tool on a lathe by the plunge cut method.
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Thread has coarse and fine pitches according to their

usage. Standard fine pitch threads, both external and
internal, are generally cut by using taps and dies. When
they are produced in large quantities, different methods are
adopted on different machine tools. However, at times, it
may be necessary to cut threads by a single point tool on
a centre lathe.
The plunge cut method of threading by a single point tool
is done by plunging the tool into the work to produce the
thread form. The tip of the tool, as well as, the two flanks
of the tool will remove metal during thread cutting and
hence the load on the tool will be more. As the possibility
of obtaining a good finish on the thread is limited, this Arrange the change gear train and set the quick change
method is applicable to fine pitch thread cutting. gearbox levers for the required pitch and hand of thread.
The following is the procedural sequence in cutting the ‘V’ Clamp the tool in the tool-post and set the tool to centre
thread by the plunge cut. height.
Grind a ‘V’ thread tool for the required thread angle. (Fig.1) Set the tool perpendicular to the lathe axis by using centre
gauge. (Fig.2)
Ensure that the thread angle ground is symmetrical with
respect to the axis of the tool.

Ensure that the top slide is set at 0°, and slackness is
removed by gib adjustment. Give successive cuts.
Set the machine to about 1/3rd of the rough turning r.p.m. For every 3 depths of cuts by the cross-slide, give one axial
cut by feeding the tool axially by half division of the
Start the machine and touch the tip to work. (Fig.3) set the compound slide. This relieves the load on the tool. (Fig.6)
cross-slide and the compound slide graduated collars to
zero, eliminating backlash.
Bring the tool to the starting point and engage the half nut.
Allow the tool to take the trial cut, the depth being given
0.05 mm divisions of the cross-slide graduated collar.
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Continue the sequence till the thread profile is formed.

(Fig.7)
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Withdraw the tool at the end of the cut and stop the
machine. (Fig.4)
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Check with the screw pitch gauge to confirm the gear box
setting. (Fig.4)
Check with the screw pitch gauge for the thread form.
Match the mating component to ensure the class of fit.
If the tool is not set square to the axis of the work, the gauge
will not match with the thread. (Fig. 8)
Reverse the machine to bring the carriage to the starting

point. (Fig.5)

In the plunge cut method of thread cutting with a single
point tool on a lathe, the accuracy of the thread is greatly
influenced by:
- The correctness of the tool profile.
- The accuracy with which the tool is set square to the
axis of the work.
- The number of plunge cuts (depth of cut) given
- The relative number of side cuts (preferably on both
flanks) given.
Effect of grinding positive back rake angle of ‘V’ thread tool
and threads cut. (Figs 9 & 10)
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Fitter - Turning
Prepare a nut and match with the bolt

• cut internal ‘V’ thread by single point threading tool
• check the metric thread using thread plug gauge
• match the nut and bolt.
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149
Job Sequence
• Check the given material for its size by steel rule. • Cut the internal thread.
• Hold the work in a three jaw chuck about 10 mm inside • Check the thread with screw pitch gauge.
the chuck. • Check the thread with external thread mating parts
• Turn the outer dia to 40 mm to possible length. Ex. 2.3.107
• Chamfer the edge 1x45° by chamfering tool. • Reverse and hold the work on ∅ 40 mm and true it.
• Centre drill, and drill a pilot of ∅ 10 mm through hole. • Face the end of the work, and maintain a total length of
20 mm.
• Enlarge the drilled hole dia 10 mm ∅ 18 mm by drilling.
• Chamfer 1x45° on the outer edge.
• Bore the drilled hole to the core (root) diameter of the
thread i.e. 19.2 mm. • Remove the sharp edges and have a final check.
• Set the machine to cut 2.5 mm pitch internal thread.
Skill Sequence
Cutting an internal thread

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• cut an internal thread on a centre lathe.
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Mount the job on four jaw chuck / three jaw chuck/ collet.
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Drill and bore the job to the core diameter of the thread to
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required length/ through hole.

For a blind hole, cut a recess at the end of the bore enough
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to permit the cutting tool to clear thread.

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The recess must be larger than the major diameter of the

thread. (Fig.1)
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Chamfer the front end to 2×45°.

Set the compound rest at 29° to cut 60° included angle as
shown in Fig.2.
Set the gear box levers to the required pitch.
Fix the correctly ground threading tool in a boring bar.
Fix the boring bar parallel to the lathe centre line and set
the point of the cutting tool to lie on the centre.
Align the cutting tool with a help of centre gauge as shown
in Fig.3.
Mark the boring bar to indicate the required depth of entry
into the bore.

Ensure that the boring bar does not foul anywhere on the At the end of the cut, simultaneously reverse the chuck
job. and clear the tool just away from the thread.
Reverse the cross slide until the tool point just touches Ensure that the tool should not touch the thread in both
the bore. side of the bore.
Set the cross-slide and compound slide graduated collars When cutting tool comes out of the bore stop the machine.
to zero.
Give the depth of cut and run the machine in forward
Withdraw the cutting tool from the bore. direction. Similarly finish the thread until final depth is
achieved.
Set the spindle speed to 1/3 of the calculated r.p.m.
Check the finished thread with a thread plug gauge or a
Start the machine.
threaded bolt.
Adjust the depth of cut to 0.1 mm.
Engage the half nut.
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Fitter - Basic maintenance
Simple repair work - simple assembly of machine parts from blue prints
• identify the defects in tail stock assembly
• dismantle the tail stock assembly
• identify the defective/worn out parts
• prepare the defective parts
• assemble in the tail stock
• check the tail stock performance.
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152
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Job Sequence
Identification of defects in a tail stock • Hence, it is known as screw rod spindle lock is not
working properly.
• Identify defect in a tail stock.
• Dismantle the spindle locking unit from the tail stock.
• Rotate the tail stock hand wheel for moving the spindle.
• Prepare the new screw rod instead of defective screw
• Lock the spindle using the locking lever. rod.
• Rotate the tail stock hand wheel and check the spindle • Assemble the prepared screw rod instead of wornout
movements and locking position. If the spindle is not screw rod.
locked properly it will move.
• Check the tail stock performance and lock the spindle
in the proper position.
Tailstock
Group Assembly Drawing
No. Qty / Description Size

On DRG Group
1 1 Tailstock
2 6 Oil nipple C8
3 1 Hex. Soc. hd. cap. screw M8 x 100
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5 1 Cyl.pin 10 x 50
6 1
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7 1
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Grub Scr. ‘G’ M8 x 16
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8 1 Grub Scr. ‘A’ M8 x 10
9 1 Sleeve
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1 Sleeve (with tenon slot)

10 1 Nut
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12 1 Screw
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13 1 Th. ball bearing (51205) 25/47 x 15

14 1 Flange
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15 1 Graduated collar
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16 1 Hand wheel
17 3 Compression spring
18 3 Steel Ball Class V 5/16” class V
19 1 Taper pin 6 x 60
20 1 Handle
21 1 Handle rod
22 1 Clamp piece
23 1 Clamp piece
24 1 Screw rod
25 1 Cap
27 1 Handle rod
28 2 Knob
29 1 Eccentric shaft
30 1 External circlip A 30
31 1 Cyl. plug 6
32 1 Spacer
33 1 Clamp nut

No. Qty / Description Size
On DRG Group
34 1 Cap
37 1 Handle rod
38 1 Tenon
39 2 Int. Thrd. taper pin 8 x 50
40 1 Gib
41 2 Spec. screw
42 1 Clamp piece
43 3 Bearing holder
3 Hex. soc. grub screw M6 x 10
44 3 Spec. pin
45 3 Needle roller bearing DL-810 8/14 x 10
46 3 Bearing bush
47 1 Shaft
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48 1 Shaft
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49 2 Wiper
50 2
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51 8 Slotted ch. hd. scr. ‘A’ M6 x 18

52 2 Wiper
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53 2 Plate
54 1 Clamp plate
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55 3 Spec. washer
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56 3 Compression spring
57 3 Spec. grub screw
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58 1 Tailstock base (For NH22)

1 Tailstock base (For NH26)
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1 Tailstock base (For NH32) M20 x 130

59 2 Stud ‘B’ (For NH22)
2 Stud ‘B’ (For NH26) M20 x 170
2 Spec stud (For NH 32)
60 1 Hex. bolt (For NH22) M20 x 140
1 Hex. bolt (For NH26) M20 x 180
1 Hex. bolt (For NH32) M20 x 220
61 2 Sef locking nut 0, 8d x M20

Rectify possible assembly faults during assembly

• dismantle the spindle and spindle pulley from drilling head
• clean and inspect the parts for worn out and damage
• assemble the spindle and spindle pulley
• test the spindle and spindle pulley for proper function
• rectify the hydraulic faults in powersaw
• dismantle and assemble the wornout grinding wheel
• dismantle and assemble the gib from the cross slide of lathe.
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156
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Job Sequence
TASK 1: Dismantle and assembly of spindle and pulley of drilling machine
• Remove the drill chuck and arbor (Part no 20 & 19) • Replace the worn out and damaged parts and assemble
from the spindle the spindle and pulley.
• Switch off the machine and remove the belt guard. • Assemble all the parts of the spindle and pulley in the
reverse order and apply, grease, oil at necessary parts.
• Remove the ‘V’ belt (Part no 1) from the pulley.
Care should be taken while fixing new bearings
Removal of spindle pulley and Hub assembly
and the circlips.
• Loosen the nuts (Part no 2) from the spindle hub (Part
• Fix the ‘V’ belt and adjust to proper tension.
no 4).
• Mount the belt guard.
• Remove the stepped ‘V” pulley (part no 3) from the
spindle hub. Test run the machine
• Remove the feather key (part no 5). • Switch on the power supply.
• Remove the internal circlips (part no 6) from spacer (part • Check the run out of the spindle by using lever type dial
no 8). test indicator with magnetic stand.
• Remove the external circlip (part no 9) from the end of • Run the machine at slow, medium and high speed
spindle hub (part no 4). atleaset 5 minutes.
• Remove the spindle hub and bearings (part no 7) from • Listen if any abnormal noise hearing from spindle
spacer. assembly.
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Use aluminium or copper rod to avoid damage • Check if any noise generating in the spindle assembly
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of hub and bearings. if so rectify the fault and run the machine without noise.
Removal of spindle sleeve
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• Remove the pinion with shaft from the machine.

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• Straighten the toothed washer (part no 11).

• Loosen and remove the nut (part no 10) from spindle
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(part no 17).
• Remove the toothed washer from the spindle.
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• Remove the bearings (part no 12 from the spindle sleeve

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(part no 14)
• Remove the O - Ring (part no 13).
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• Remove the spindle sleeve (part no 14).

• Remove the spindle (part no 17) from the spindle
sleeve.
• Remove the thrust bearing (part no 15) from spindle
using hydraulic press.
• Clean all the dismantled parts and dry it.
Keep all the disassembled parts in a separate
tray in proper order while dismantling.
Identification of worn out and damaged parts
• Check all dismantled parts of spindle and pulley,
thoroughly and list out the damaged, worn out parts and
fill up the table given.
Table
Sl.No. Name of the parts Remarks
1
2
3
Parts 11 Washer
1 ‘V’ Belt 12 Bearing
2 Nut 13 O-Ring
3 Spindle pulley 14 Spindle sleeve
4 Spindle hub (Internal splines) 15 Thrust bearing
5 Feather key 16 Splines on spindle
6 Internal circlip 17 Spindle
7 Bearing 18 Wedge slot
8 Spacer for bearing 19 Chuck arbor
9 External circlip 20 Drill chuck
10 Nut
TASK 2: Rectification of hydraulic fault in power saw
• Switch off the machine and remove the belt guards. • Clean all the parts and dry it.
• Support the arm properly. • Inspect oil flow part with compressed air.
• Drain the hydraulic oil and keep it safely. • Inspect the oil seal/ ‘o’ rings/filter control valves/ valve
seat.
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• Remove the connecting pin/circlip/split pin and loosen
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the fasteners in the hudraulic unit. • Replace / repair the worn out/damaged parts.
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•
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Disconnect the oil lines and remove the hydraulic unit Assemble the hydraulic unit in the reverse
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from the m/c. manner of dismatling.
• Dismantle the hydraulic unit and keep it in a separate • Fix unit to the machine.
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tray Fig 2. • Check the condition of drained oil if condaminated fill

as per manufacturers recommended grade oil.
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• Connect the oil lines & drive system and remove the
arm support.
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• Trail run the machine and observe the performance.

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• Check any leakage in the oil line, if found arrest them.

• Adjust the control valve and verify to arm lifting &
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descending performance.
• Fix the belt guards.

TASK 3: Dismantling and assembling of a worn out grinding wheel
• Switch-off the electrical power supply. • Dismantle the wheel spindle from the wheel head.
• Dismount the safety glass bracket. • Extract the ball bearings from the housings/spindle.
• Remove the grinding wheel covers. • Clean the ball bearings and other parts.
• Unscrew the nuts from the spindle of the grinding wheel. • Inspect the bearings and other parts.
• Remove the tool rest. • Replace the bearings, if necessary.
• Remove the grinding wheels from the spindle. • Change the belts, if damaged.
• Remove the belts from the motor pulley. • Lubricate the bearings and other parts.
• Disengage the grinding wheel head unit from the main • Assemble the parts in the reverse sequential order.
body.
• Replace the grinding wheels, if necessary.
• Check the smooth running of the bench grinder.
TASK 4: Dismantling and assembling of gib from the cross slide of a lathe
• Remove the adjusting screws from the dovetail slide.

• Dismantle the gib from the cross slide.
• Clean the slide surfaces.
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• Check and inspect all the parts.
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•
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Damaged parts of gib strip and adjustment screws
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should be replaced.
• Lubricate the slide ways.
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• Assemble the gib and check the gib seating.

• If you find any defects, rectify it.
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• Check adjusting screws thread.

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• Lubricate the slide ways of gib strip.

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• Assemble slide way, gip strip with saddle.

• Tighten the adjusting screws to give the correct free-
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dom required in the assembly.

• Lock the movement of the adjusting screw by the check
- nut.
• Check the slide ways smooth movement without any
shake.
• If taper gib is provided in the assembly, properly posi-
tion the gib by end screws.

Skill Sequence
Fit a new grinding wheel -Task 3

• fit a new grinding wheel in pedestal grinding machine.
Switch off the power supply to the machine

Clean the machine and remove any loose metal or abrasive
particles.
Loosen the work rest clamp and remove the rest Fig 1.
Remvoe the outer plate of the whell guard Fig 1.
The wheel clamping nut is now accessible.
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Check the nut direction before loosening.

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Loosen the nut using a spanner of the correct size Fig 2.

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Remember that when facing the front of the

machine, the spindle on the left has a left-hand
thread. Turn the nut clockwise to loosen it.
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Remove any paper, washer that has adhered to the flange

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Fig 5.
Remove the nut and the outer flange Fig 3.

A light blow with a soft hammer may be
needed to free it from the wheel.
Clean the flange, spindle, thread and inside the guard.
Remove the worn out wheel from the spindle and place it
in the scrap bin. Check that both the paper washers are intact in the new
wheel.
Check that the markings on the old wheel are the same
as those on the new wheel Fig 4. Try the new wheel on the spindle Fig 6.

Turn the spindle and wheel a complete revolution.
Ensure that the wheel is running true, by rotating hand
and it is clear of the inner part of the guard.
Tighten the nut sufficiently enough to ensure that the
flanges will drive the wheel without slipping Fig 9.
Scrape the lead bush to abtain a correct fit.

The outer diameter of the new wheel should
fit neatly inside the wheel guard, but with
adquate clearance.
Push the wheel carefully against the driving flange and
place the outer flange in position Fig 7. Refit the outer plate of the wheel guard Fig 10.
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Screw up the clamping nut by hand, firmly enough to hold

the wheel in position Fig 8. Reset the work rest as close to the wheel face as possible.
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Tighten the work rest clamp firmly.

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Rotate the wheel again by hand ensure that the wheel

runs freely and true.
(Switch on the power supply and start the machine).
Allow the wheel to operate for one minute at full operating
speed.
The machine is now ready for grinding operations.

Adjust the gib strip - Task 4
• adjust and align the gib strip in a lathe.
Loosen the lock-nuts. (Fig 1) Clean all the parts.

Check the straightness of the gib using Prussian blue.
Scrape the gib to get even surface to prevent stick-slip
motion of the cross-slide.
Lubricate all the parts.
Assemble the gib into the dovetail slide and position it.
(Fig 4)
Remove the set screws. (Fig 2)
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Adjust the screws and eliminate the clearance between
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assembly.
Lock the movement of the adjusting screws by the check-
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nut.
Pull the gib out. (Fig 3)
Hold the gib in correct position firmly while locking with
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check-nuts.
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Check the function of the cross-slide.

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Perform the routine maintenance with check list

• perform the routine maintenance with check list
• rectify the defective items found.
Job sequence
• Check the tension of the belt and adjust
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TASK 2: Check the movement of the carriage of the lathe

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• Run the machine on different spindle speeds and check

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the speed.
• Engage the power feed and check the longitudinal and
transverse feed movements.
• Check the function of clutches by operating the clutch
lever.
164
• Check the movement of the cross-slide and the
compound slide.
• Check the oil level and the functioning of the

lubricating pump.
• Check the coolant level and the functioning of the
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coolant pump.
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• Check the safety guards and ensure that they are

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in postion.
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Inspect the following check list items of centre lathe
and tick it in appropriate column.
Table
Items to be checked Good working/Satisfactory Defective Remedial measures to be carried out
Belt and its tension
Bearing sound
Driving clutch and brake
Exposed gears
Working in all the speeds
Working in all feeds
Lubrication system
Coolant system
Carriage & its travel
Cross-slide & its movement
Compound slide & its travel
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Tailstock’s parrallel movement
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Electrical controls
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Safety gaurds
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Monitor machine as per routine check list

• inspect the lathe parts
• applying lubrication to lathe parts
• operate and check the movements of the machine parts, before machining.
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167
Job Sequence
• Clean the machine.
• Check the safety guards (Fig 1) and ensure that they
are in position.
• Check the tension of belt.
• Check the free movement of carriage, tailstock of the
lathe.
• Run the machine on different spindle speeds and check.
• Engage the power feed and check the longitudinal and
transverse feed movements.
• Check the function of clutches by operating the clutch
lever.
• Check the movement of cross slide and the compound
slide.
• Check the oil level and functioning of the lubrication.
• Check the coolant and the functioning of the coolant
pump.
• Check the exposed gears are fitted proerly switch ON
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and check the running condition of machine before
machining.
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Routine check list of lathe

Table
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Items to be checked Description Remarks

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Belt and its tension

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Bearing sound
Driving clutch and brake

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Exposed gears
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Working in all the speeds
Working in all feeds
Lubrication system
Coolant system
Carriage & its travel
Cross-slide & its movement
Compound slide & its travel
Tailstock’s parrallel movement
Safety gaurds
Adjustment screw
Quick change gear box
Feed selector

Read pressure gauge, temperature gauge, oil level

• read pressure gauge
• read temperature gauge
• check the oil level.
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Note: Instructor shall demanstrate to the

trainees regarding, reading of pressure gauge,
temperature gauge and oil level.
169
Set pressure in pneumatic system

• set the pressure relief valve
• check the function of relief valve.
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170
Job Sequence
• Switch on the compressor • Open the cap
• Read the pressure gauge in the compressor tank. • Adjust the set screw No.5 in the Fig.
• Close the outlet line. • Adjust the set screw according to the required pres-
sure.
• Check the relief valve function according to the work-
ing pressure system • Check the function of the pneumatic system
• It not functioning properly, do the following.
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Assemble simple fitting using dowel pins and cap screw assembly using
torque wrench
Objectives : At the end of this exercise you shall be able to
• prepare and assemble the assembly fit using dowel pins and cap screws.
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172
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Job Sequence
• Check the raw materials size • Fit, part 2 in part 1 and 3 maintaining tolerance
± 0.04mm.
• File part 1, 2 and 3 to over all size maintaining parallel-
ism and perpendicularity. • Assemble, part 1, 2 and 3 all together and clamp it
using parallel clamps maintaining squareness.
• Check the faltness and squareness with try square
and dimensions with vernier caliper. • Hold the assembly setting in drilling machine table
along with suitable fixtures.
• Apply marking media on part 1 and 3 and mark the
dimensional lines as per drawing. • Drill, counter sink and ream the hole as per drawing
and fix ∅ 5mm dowel pin without disturbing the
• Punch witness mark and drill hole marks
assembly setting.
Part 1 & 2
• Similarly, drill, counter sink and ream the other dowel
• Chain drill, cut and remove the excess metal and file pin hole without disturbing the assembly setting and
to size and shape as shown Fig 1. fix other ∅ 5mm dowel pin.
• Drill holes for tapping in part 1 and 3 withsout disturbing
• Separate the assembly setting, drill ∅ 6.6mm through
hole and ∅ 11mm counter bore to the depth of 8mm in
part 3 to enter the cap head screws as shown in job
drawing.
• Hold part 1 in bench vice and cut M6 internal thread in
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two holes to fix cap head screws.
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• Clean the threads without burrs.
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• Finish file in part 1, 2, 3 and de-burr in all corners of the
job.
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• Similarly, chain drill, cut and remove the excess metal • Re-assemble part 1 and 3 along with dowel pins and
in part 3 and file to size and shape as shown in Fig 2. cap screws.
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• Fit, part 2 in part 1 and 3 opening slot.

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Skill Sequence
Fixing of dowel
• fix dowel pins
• remove dowel pins.
Keep position 1 and position 2 as shown in Fig 1. Drive the dowel using a hammer such that about 5 mm of
the chamfer side of the dowel enters into the reamed hole
Tighten the socket head screw such that there is a gap of
as shown in Fig 2.
one pitch of the socket head screw as shown in Fig 1.

Drive the dowel keeping pin punch dia 5.8 over the radius
of the end of the dowel such that the chamfered end of the
dowel into position 2 as shown in Fig 4.
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in Fig 5.
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Check for the perpendicularity.

Drive the dowel into the reamed hole such that chamfered
end of the dowel enters fully into the position 1 as shown
in Fig 3.
Tighten the socket head screw such that there is no gap
exists as shown in Fig 6.

Removal of the dowel Knock the dowel out using the hammer as shown in Fig 8.
Removal of the dowel should be in the same direction as
driving.
Insert pin punch into the reamed hole such that it sits over
the radius end of the dowel as shown in Fig 7.
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FITTER

SECTOR: Production & Manufacturing

DIRECTORATE GENERAL OF TRAINING

Copyright © 2018 National Instructional Media Institute, Chennai

All rights reserved.

for their contribution in bringing out this publication.

New Delhi - 110 001

MEDIA DEVELOPMENT COMMITTEE MEMBERS

Shri. M. Sampath _ Training officer (Retd.)

Shri. M. Sangarapandian _ Training officer (Retd.)

Shri. K. Kesavan _ Asst. App. Advisor Junior (Retd)

Shri. C.C. Subramanian _ Training officer (Retd.)

Shri. K.B. Shivaramu _ Junior Training officer

Government ITI, Mysore - 570007

Shri. D.C. Nataraja _ Junior Training officer

Government ITI, Mysore - 570007

Shri. Milind Rasu _ Instructor, Government ITI

Shri. K. Srinivasa Rao _ Joint Director,

Co-ordinator, NIMI, Chennai - 32

Shri. G. Michael Johny _ Assistant Manager,

Module 1 Drilling 150 Hrs

bl I Total 550 Hrs

for improving the manual.

Exercise No. Title of the Exercise Page No.

2.1.61 Mark off and drill through holes 1

2.1.62 Drill on M.S Flat 4

2.1.63 File radius and profile to suit gauge 6

2.1.64 Sharpening of drills 10

2.1.65 Practice use of angular measuring instrument 16

2.1.67 Drill through hole and blind holes 23

2.1.69 Prepare studs and bolt 31

2.1.73 Make simple open and sliding fits 42

2.1.74 Enlarge hole and increase internal dia 45

2.1.75 File cylindrical surfaces 47

2.1.76 Make open fitting of curved profiles 49

2.1.77 Correction of drill location by binding previously drilled hole 52

2.1.78 Make inside square fit 54

Module 2: Fitting assembly

2.2.79 Make sliding ‘T’ fit 56

2.2.80 File fit - combined, open angular and sliding sides 59

2.2.81 File internal angles 30 minutes accuracy open, angular fit 61

2.2.82 Make sliding fit with angles other than 90° 63

2.2.84 Make and assemble, sliding flats, plain surfaces 72

2.2.88 Fasten mechanical components/sub-assemblies together using screws,

2.3.90 Lathe operations 89

2.3.91 True job on four jaw chuck using knife tool 91

2.3.92 Face both the ends for holding between centres 94

2.3.93 Using roughing tool parallel turn ± 0.1 mm 96

2.3.95 Holding job in three jaw chuck 101

2.3.98 Sharpening of - single point tools 113

2.3.99 Cut grooves - square, round ‘V’ groove 116

2.3.100 Make a mandrel - turn diameter to sizes 118

2.3.101 Knurl the job 121

2.3.104 Turn taper (internal and external) 133

2.3.105 Turn taper pins 138

2.3.106 Turn standard tapers to suit with gauge 140

2.3.107 Practice threading using taps, dies on lathe by hand 142

2.3.108 Make external ‘V’ thread 144

2.3.109 Prepare a nut and match with bolts 149