Fitter Questions

1) Define Tolerance? Why is tolerance given in machining of a Work Piece.

Tolerance is the total amount a dimension may vary and is the difference
between the upper (maximum) and lower (minimum) limits. Because it is
impossible to make everything to an exact size, tolerances are used on
production drawings to control the parts.

2) Define various types of tolerance used measurement?

Three types of tolerances used in measurements: Unilateral
tolerances. Bilateral tolerances. Compound tolerances

3) Differentiate between Unilateral and Bilateral Tolerance?

A unilateral tolerance exists when a target dimension is given along with a
tolerance that allows variation to occur in only one direction. deviate in one
direction. A bilateral tolerance exists if the variation from a target dimension is
shown occurring in both the positive and negative directions.

4) What is a hole basis system?

In the hole basis system, the basic diameter of the hole is constant while the
shaft size varies according to the type of fit.

5) What is a shaft basis system?

Shaft basis system: In this system, the size of the shaft is kept constant, and the
diameter of the hole is varied to give the various fits.

6) Define Fit and various types?

The tightness or looseness of two mating parts is known as Fit.
There are mainly three types of fit and those are: Clearance Fit. Interference Fit
and. Transition Fit.

7) What is Honing Process?

Honing is an abrasive machining process that produces a precision surface on a
metal workpiece by scrubbing an abrasive grinding stone or grinding wheel
against it along a controlled path. Honing is primarily used to improve the
geometric form of a surface, but can also improve the surface finish.
8) What is single point cutting tool and multi point cutting tool?
A single-point cutting tool is defined as a tool with only one main cutting
edge similarly, double-point cutting tools have two cutting edges, and multi-
point cutting tools have two or more main cutting edges.

9) Differentiate between honing and lapping process?

Lapping is a sanding or polishing method used to create an accurate finish on a
flat or domed surface of a part. Honing is a method of internal grinding used to
achieve a precise surface finish and shape on the inside diameter (ID) of a tube,
bore, or hole. The honing and lapping processes are both highly controlled.

10) Name any 5 multi point cutting tool.

Milling cutters, Hobs, Broach, Grinding wheels, Reamer, and Knurling tool,
etc.

11) Name any 5 single point cutting tool.

Turning tool, Shaping tool, Planing tool, Slotting tool; Boring tool; Fly
milling cutter, etc.

12) Define Creep and its types?

Creep (sometimes called cold flow) is the tendency of a solid material to move
slowly or deform permanently under the influence of persistent mechanical
stresses. It can occur as a result of long-term exposure to high levels of stress
that are still below the yield strength of the material.
The creep test is divided into three stages—primary creep, secondary creep and
tertiary creep.

13) What is Morse Taper?

A Morse taper is a standard system for securely attaching drill bit tools to
the drill press machine spindle. Morse tapers will narrow approximately 5/8 inch
(1.5 centimeters) per foot (30.4 centimeters).
14) What is least count?
The smallest value that can be measured by a measuring instrument is called its
least count.
15) How to calculate the least count of Vernier caliper?
Least Count = Minimum size that can be measured with main scale
alone(MSD) / the total number of divisions on Vernier/circular scale(VSD).
Thus in short-form, it can be written as, L.C.=MSD/VSD.

16) What is snap gauge?

It is a limit gauge with permanently or temporarily fixed measurement
aperture which is used to quickly verify whether an outside dimension of a part
matches a preset dimension or falls within predefined tolerances.

17) What is plug gauge?

Plug gauges are used to check the inside diameters of parts. They are
cylindrical in shape and come in pairs, Go and No-Go. One of them has a
dimension at the maximum limit, the other is at a minimum limit. This is
according to the size of the hole the gauge is to inspect.

18) What is hot working and Cold working process?

“Hot working” has to be carried out in general at the temperature above
“recrystallization temperature”. But carried out below the “Melting point” of
metal. Whereas “cold working process” has to be carried out below the
“recrystallization temperature”.

19) What is feller gauge?

A feeler gauge is used to measure or set very small gaps, normally under 1
mm. When the blades are folded back into the handle, the thin, delicate blade
are protected. The thickest possible blade that can be inserted into a gap or
crack shows its width.

20) Differentiate between extrusion and Drawing in metal forming process?

Extrusion-- shaping a solid of constant cross-section by squeezing metal
through a die. Drawing -- shaping a solid of constant cross-section by pulling
solid metal through a die.

21) Differentiate between forward and backward extrusion?

This process is called a backward extrusion process as the flow of material is
in a direction opposite to the movement of the ram. In the forward extrusion
 process the flow of material and ram movement where both in the same
direction.

22) Difference between Boring and Drilling?

Drilling is the primary process used to create the hole, while boring is a
secondary process that can enlarge or finish a preexisting hole.

23) Define the various valid drawing projections used in Engineering

Drawing?
1st angle projection and 3rd angle projection (2nd and 4th are not taken in
consideration)

24) What is first angle projection?

First Angle Projection: In the first angle projection, the object is placed in the
1st quadrant. The object is positioned at the front of a vertical plane and top of
the horizontal plane. First angle projection is widely used in India
(Recommended by BIS) and European countries

25) What is third angle projection?

In this type of projection, the object is imagined to be in the third quadrant.
Again, as the observer is normally supposed to look from the right side of the
quadrant to obtain the front view, in this method, the projection plane comes
in between the observer and the object.
26) Why 2nd angle projection is not used?
As per the rule of projection when the horizontal plane is rotated 90 degrees in
a clockwise direction, top and front views will overlap. Overlapping
projection views create confusion in the drawing. Therefore the 2nd angle
projection system is not used to draw engineering drawings. (Same goes for
4th angle projection)

27) Define milling operation?

Milling is a process where a milling tool cuts away the material in a rotary
motion. As with drilling, this is possible with a wide array of different tools
with different diameters and different hardness's. Because the mill is moving,
the rotational speed must be high in order to get a clean finish of the milled
hole.

28) Differentiate between up milling and down milling?

In up milling (conventional milling), the feed direction of the cutting tool is
opposite to its rotation.
In down milling (climb milling), the cutting tool is fed with the direction of
rotation.

29) What is tool life?

Tool life - The actual machining time between two successive sharpening’s of
cutting tool is called Tool life. Tool life is used to calculate the tool material
performance and machinability of workpiece material.

30) What is tool life equation?

Taylor's tool life equation As per F.W. Taylor, the relationship between
Cutting Speed and Tool Life can be expressed as
VTn = C
Where,
V= Cutting speed (m/min)
T= Tool life (minutes)
n= a constant whose value depends upon the material of the cutting tool &
job, called tool life Index.
(Commonly, n=0.08 to 0.02 for H.S.S tools, n=0.2 to 0.4 for cemented carbide
tools, n= 0.5 to 0.7 for Ceramic Tools, n = 0.1 to 0.15 for cast alloys)
C = a constant, called machining constant
31) Composition of HSS steel ?
A common type of high-speed steel contains 18% tungsten, 4% chromium,
1% vanadium, and only 0.5–0.8% carbon.

32) What is destructive and Non-destructive test?

Destructive testing is conducted by damaging the specimen that is being
tested. In contrast, during non-destructive testing (NDT), the tested item does
not suffer any physical damage and can be used in active operation after the
testing.

33) Name any 5 Non- destructive test?

 Ultrasonic NDT (UT)
 Radiography NDT (RT)
 Eddy Current NDT (ET)
 Magnetic Particle NDT (MT)
 Liquid penetrant testing. NDT (LPT)
 Dye Penetrant NDT (PT)

34) Name any 5 hardness test?

The Brinell test, the Vickers Diamond test, and the Rockwell test, Mohs test,
Shore test and Knoop test.

35) What are sine bars?

A sine bar consists of a hardened, precision ground body with two precision
ground cylinders fixed at the ends. The distance between the centers of the
cylinders is precisely controlled, and the top of the bar is parallel to a line
through the centers of the two rollers. The dimension between the two rollers
is chosen to be a whole number (for ease of later calculations) and forms
the hypotenuse of a triangle when in use.

36) What are marking tools?

What is Marking Tool? The marking tool is used to mark on a job or
workpiece to obtain accurate size and shape. Before using marking tools on a
job or workpiece, firstly we should use marking media on it so that we can
clearly see when marking.
37) Differentiate between Shaper and Planer Machine?

In a shaper machine work is held

stationary and the cutting tool on the In a planar machine, the tool is
ram is moved back and forth across the stationary and work piece travels
work. back and forth under the tool.

A planer is meant for larger jobs than

can be undertaken on a shaper. Jobs
Shaper can be used for shaping much as large as 6-meter-wide and twice
smaller jobs. as long can be machined on a planer.

A shaper is a light machine. A planer is a heavy-duty machine.

Shaper can employ light cuts and finer Planer can employ heavier cuts and
feed. coarse feed.

Planer uses several tools to cut

Shaper uses one cutting tool at a time. simultaneously.

The shaper is driven using quick return The drive on the planer table is either
mechanism. by gears or by hydraulic means.

38) Differentiate between Jig and fixture?

The main difference between a jig and a fixture is that a jig is versatile. It can
be used for both holding the workpiece and guiding the tool whereas a fixture
is used only to hold the workpiece.

39) What is annealing?

It is the process of heating a metal in a furnace above it's recrystallization
temperature and allow it to cool inside the furnace. First the temperature of the
material is raised. Secondly the material is soaked in that temperature for few
hours. Third, the temperature is lowered and the material is allowed to cool
 inside the furnace. Annealing improves ductility, strength and good elongation
properties.

40) What is normalizing/

The process is similar to that of annealing, but after soaking stage the material
is taken out from the furnace and allowed to cool in atmosphere. The
properties of the material are bit lower than that of annealing because of
different cooling areas in the material.

41) What is quenching?

Quenching is the process of heating the material above the recrystallization
temperature and cooling it suddenly in a water bath or oil bath or in polymers.
Type of quenchant depends upon the application.

42) Name various quenching methods?

Quenching mediums include oil (commonly used in industry), water, brine

and air. Depending on the cooling rate, as high as 8.3oC/s [1], the mechanical
and metallurgical properties of the metal can be changed in order to achieve the
specific design parameters that are required by the part for a specific purpose.

43) Which type of coupling is used for coupling a pulley and a shaft?

A. Taper key
B. Woodruff key
C. Gib head key
D. Flat saddle key

44) A key is subjected to?

A. Shear stress
B. Compression stress
C. Tensile stress
D. Twisting stress

45) Which finishing process has high degree of dimensional accuracy?

A. Drilling
B. Turing
C. Grinding
D. Lapping

46) What is the use of a try square?

A To check right angle
B To check acute angle
C To check obtuse angle
D To check straight angle

47) The No. of tolerance grades in IS system of limit are

A 14 grades of tolerance
B 16 grades of tolerance
C 18 grades of tolerance
D 20 grades of tolerance

48) Name the property of metal which can be drawn into wire without rupture.
A Ductility
B Tenacity
C Elasticity
D Malleability

49) What is the use of feeler gauge?

A Check the width
B Check the height
C Check the length
D Check the gap between the mating parts

50) Which file is used to make the job close to the finishing size?
A Single cut file
B Curved cut file
C Second cut file
D Double cut file

51) Which file has the parallel edges throughout the length?
A Hand file
B Bastard file
C Rasp cut file
D Single cut file

52) What is the material to manufacture bench vice?

A Tool steel
B High carbon steel
C Medium carbon steel
D Cast iron

53) Name the property of metal to resist the effect of tensile forces without
rupture.
A Ductility
B Tenacity
C Elasticity
D Malleability

54) Which type of taper is provided in the drill shank?

A Pin taper
B Metric taper
C Morse taper
D Jerno taper

55) What is the unit of feed in drilling?

A m/rev
B mm/rev
C m/min
D mm/min

56) Which file is having rows of teeth cut in one direction?

A Single cut file
B Curved cut file
C Second cut file
D Double cut file

57) What is the use of bevel protractor?

A Check the length
B Set the work piece
C Measure the angle
D Measure the depth

58) What is the accuracy of Vernier bevel protractor?

A 1°
B 5°
C 5’
D5“

59) How the drill chucks are held on the machine spindle?
A By arbor
B By sockets
C By sleeves
D By special clamp

60) How much carbon content of steel is forgeable?

A Up to 1.2 %
B Up to 1.7 %
C Up to 1.9 %
D Up to 2.1 %

61) What is the material of solder?

A Welding rod
B Synthetic element
C Pure metal or alloy
D Non-metallic element

62) What is the material used to manufacture rivets?

A Rubber
B Synthetic
C Hardened steel
D Mild steel

63) Datum line is also known as

A. Centre line
B. Outline
C. Reference line
D. None of these.

64) Which Drilling Machine is used for drilling holes where electricity is not
available?
A. Bench drilling Machine
B. Pillar drilling Machine
C. Ratchet drilling Machine
D. Radial drilling Machine

65) Bolt heads are manufactured by?

A. Swagging
B. Roll forging
C. Tumbling
D. Upset forging

66) Which pipe fitting is used to divert the flow direction of pipe?
A Union
B Plug
C Elbow
D Coupling

67) Where universal coupling is used?

A Automobile vehicles
B Textiles mills
C Engineering machines
D Large angle drive

68) What is the advantage of annealing ?

A To relieve the internal stress
B To add cutting ability
C To refine the grain structure of the steel
D To increase wear resistance

69) What quenching media is used for special alloy steels?

A Brine solution
B Water
C Oil
D Cold Air

70) What is the process to add cutting ability and wear resistance on steel?
A Tempering
B Annealing
C Normalising
D Hardening
 Welding

1. Which type of filler rod is used in gas welding of stainless steel?

A Pure aluminium
B Copper silver alloy
C Columbium stainless steel
D Cop

What is the function of AC welding transformer?

A It converts to low voltage high current ampere
B It converts to high voltage and low current ampere
C It converts to low voltage and low current ampere
D It converts to high voltage and high current ampere

What is the disadvantage of AC welding transformer?

A More initial cost
B Not free from arc blow
C More maintenance cost
D Not suitable for welding non-ferrous metal

What is the colour painted on the acetylene gas cylinders?

A Black
B Green
C Blue
D Maroon

What is the name of distortion occurs in the weld direction?

A Angular distortion
B Bending distortion
C Longitudinal distortion
D Transverse distortion

What is the equipment used to protect the body from flying spark during gas
cutting?
A Leather cap
B Leather apron
C Leather shoes
D Cutting goggles

Which internal defect in welding is invisible to naked eye?

A Spatter
B Porosity
C Undercut
D Stray arc
 Turner

Which drilling machine is used in Mass Production?

A. Bench type drilling machine
B. Pillar type drilling machine
C. Portable type drilling machine
D. Gang type drilling machine

Dressing of grinding wheel refers to

A. Restoring the cutting action of wheel
B. Shaping the wheel
C. Making the wheel concentric to axis
D. Changing the wheel