FITTING SHOP

AIM OF THE EXPERIMENT: To study about different hand tools used in fitting shop.

Theory:
Components may be produced by working on metal either on a machine tool or on the bench.
Sometimes it becomes necessary to replace or repair a component which must fit accurately with
another component on re-assembly. This involves a certain amount of hand fitting. The assembly
of machine tools, jigs, gauges, etc. involves certain amount of bench work. The accuracy of work
done depends upon the experience and skill of the fitter. Metal removal at the bench requires the
use of a number of simple hand tools and considerable manual effort. Working on components
with hand tools and instruments, mostly on workbenches is generally referred to as, ‘fitting
work’. The hand operations in bench work consist of filing, chipping, scraping, sawing, drilling,
tapping, grinding etc.

Material Used: Mild steel also known as plain-carbon steel and low-carbon steel, is now the
most common form of steel because its price is relatively low while it provides material
properties that are acceptable for many applications. It contains a small percentage of carbon
approximately 0.05–0.25%.

 Properties of Mild Steel:

 High tensile strength.
 High impact strength.
 Good ductility and weldability.
 A magnetic metal due to its ferrite content.
 Good malleability with cold-forming possibilities.
 Not suitable for heat treatment to improve properties.

Practical Application of Mild Steel:

 Steel Frame Buildings.

 Gates and Fencing.
 Machinery Parts.
 Pipelines.
 Furniture and decorations
 Wire/Fencing
 Nails etc
TOOLS AND EQUIPMENT REQUIRED IN THE FITTING SHOP:
Both the bench work and fitting require the use of a number of simple hand tools.
1. MARKING AND MEASURING TOOLS
i) Steel rule- It is used for measurement of length. It is usually graduated in millimeter
and inches. Its least count is 0.5 mm or 1/64 of an inch. For accurate reading it is
necessary to read vertically to avoid errors arising out of parallax.

(ii) Scriber- A scriber is a slender steel tool used to scribe or mark lines. It is made
up of high carbon steel which is hardened.

(iii) Punch- It is a marking tool used for marking ‘dots’ .

These are of three types:
1. Centre Punch (90º) - I t is used for locating centre of holes.
2. Dot Punch (60º) - It is used for weakness marking.
3. Prick Punch (30º) – It is used for light punch marks
(iv) Try square - It is used for checking squareness and flatness of a surface. Try
square consists of rectangular steel blade fixed rigidly to cast iron stock. The
length of blade varies from 150 mm to 300 mm

Fig. Try Square

(v) Angle plate- It is placed over the surface plate for supporting jobs at the time of
marking. It is made of cast iron.

(vi) Outside caliper- It is a device used for measuring and transferring the outside
dimensions of components.
(vii) Inside caliper- It is used for measuring inside dimension of components.
(viii) Dividers- It is used for marking, drawing arcs, circles, laying out perpendicular
lines, bisecting lines etc.

Outside Caliper Inside Caliper Divider

(ix) Steel tape- It is used for measuring length.

(x) Spirit level- It is used for testing the levels of Horizontal, vertical and Inclined
surfaces.
(xi) Straight edge- This tool is used for testing the straightness and flatness of plane
surfaces.

(xii) Surface plate- It is used for marking purpose. The job is placed over the surface
plate and marked with the help of Bevel protractor. It is made of cast iron. It is
usually rectangular in shape and have a flat surface

(xiii) Vernier caliper- Vernier caliper is a precision measuring instrument of outside

diameter, inside diameter and depth. The least count of vernier scale may be 0.001
inch system, 0.02mm metric system.
(xiv) Vernier Height Gauge- It is similar to vernier calipers and used for marking
purpose. It consists of scriber by which lines are scribed on the job.

(xv) Universal scribing block- It is also for scribing lines for layout work and
checking parallel surfaces.
(xvi) Outside micrometer- It is a measuring instrument used for measuring external
dimensions accurately. They are available in different ranges outside micrometer
list count of 0.001mm.
b. CUTTING AND FINISHING TOOLS:
(i) Chisels- Chisel is a single point cutting tool. It is used for removing surplus metal
or for cutting sheets. The tools are made from 0.9% to 1.0% carbon steel of
octagonal or hexagonal section.

(ii) Hacksaw- Hacksaw is a multi-point cutting tool. It is used for cutting metal by
hand with a frame which holds a thin blade, finally in position. The blade has a
number of cutting teeth. The number of teeth per inch is selected on the bit of
types of job.

FIXED FRAME HACKSAW ADJUSTABLE FRAME HACKSAW

(iii) Scraper- It is a single point cutting tool. It is used for obtaining a fine surface
finish on the work by removing convex spots from machined surfaces. Scrapers
may be flat, triangular and half-round. The material is good quality forged steel
and cutting edge is usually left very hard. Scrapers are made in a variety of
 lengths from 100mm onwards and in many shapes.
(iv) Taps and Tap Wrenches- A tap is a hardened steel tool, used for cutting internal
threads in a drilled hole. Hand taps are usually supplied in sets of three for each
diameter and thread size. Each set consists of a taper tap, intermediate tap and
plug or bottoming tap.

Tap Wrench

(v) Dies and Die-holders- Dies are the cutting tools used for making external
threads. Dies are made either solid or split type. They are fixed in a die-holder for
holding and adjusting the die-gap. They are made of tool steel or high carbon
steel.

(vi) Reamer- A reamer is a multi-point cutting tool used for enlarging and finishing
previously drilled holes to accurate sizes. Reaming produces high quality surface
finish and dimensional accuracy to close limits. Also small holes which cannot be
finished by other processes can be finished.
(vii) Combination Cutting Pliers - This is made of tool steel and is used for cutting as
well as for gripping the work.
(viii) Twist Drill- Twist Drills are used for making holes. These are made of high
speed steel. Both straight and taper shank twist drill are used. The following are
the sizes and designations of twist drills.
 Millimeters from 0.4 mm onwards
 Inches from 1/16” onward
 Letter Drills A to Z
 Number drills 60 to 20
 Taper shank drills 3 to 100mm

(ix) Files - Filing is one of the methods or removing small amount of material from
the surface of a metal part. A file is a hardened steel tool, having slant parallel
role of cutting edges or teeth on its surfaces. On the faces, the teeth are usually
diagonal to the edge. One end of the file is shaped to fit into a wooden handle.
The hand file is of parallel width and tapering slightly in thickness, towards the
teeth. It is provided with double cut teeth on the faces, single cut on one edge and
no teeth on the other edge, which is known as the safe edge. Files are classified
according to their shape, cutting teeth and pitch or grade of the teeth based on the
coarseness or the pitch of the teeth.
Flat file: Flat files are of rectangular cross-section. The edges along the width of
these files are parallel up to the 2/3rd of the length, and then they taper towards the
point. The faces are double cut and the edges single cut. They are useful for filing
and finishing external and internal surfaces.
Hand file: these files are similar to the flat files in their cross section. The edges
along the width are parallel throughout the length. The faces are double cut. One
edge is a single cut whereas the other is a safe edge. These are useful for filing
surfaces which are at right angles to surfaces already finished.
Files can also be classified and named according to thier
a) Sizes,
b) Type or cut of teeth.
• Size: The size of a file is its length. This is the distance from the point to the heel, without
the tang.

• Cut of teeth: Cuts of files are divided into two groups: (1). single cut (2) Double cut. On
single cut files the teeth are cut parallel to other across the file is an angle of about 60° to
the centre line of the file. Double cut files have two sets of teeth; the over cut teeth being
cut at about 60° and the up cut at 75 to 80° to the centre line. Single cut and double cut
files are further divided according to the coarseness or spacing between the rows of the
teeth. In descending order of roughness, they are listed as,
1. Rough (R) 2. Bastard (B) 3 Second cut (SC) 4. Smooth (s) 5. Death smooth (DS)

2) Striking Tools:
An Engineers hammer is a hand tool for striking purpose while Punching, Bending,
Straightening, Chipping, And Forging, Riveting can be done.
Main Parts of a Hammer:
1. Face
2. Peen
3. Cheek
4. Eyehole

Types of Hammer (On the Basis of their pein shape)

 Ball Pein Hammer : The Pein of the hammer is spherical in shape. It have a flat circular
face.
 Straight Pein Hammer : This hammer also have circular flat face and pein is tapered
towards the end in such a way that the pein axis is Parallel to the axis of hammer.
 Cross Pein Hammer : This hammer is similar to the straight pein hammer. The only
difference is the axis of pein is perpendicular to the axis of hammer.
 SQUARE FIT
EXPERIMENT NO: DATE: / / 20

AIM OF THE EXPERIMENT: To make a Square fit from the given mild steel pieces
with specified dimensions
MATERIALS REQUIRED: Mild steel flat (48 X 48 X 5mm).
TOOLS AND EQUIPMENT REQUIRED:
1.6” try square
2. 6” scriber
3. Odd leg caliper
3.12” hack saw Frame
4 Blades (12 TPI)
5. 10” rough file
6. 10” smooth file
7. 10” Square file
8. Dot punch
9. Ball peen hammer.
10. Steel Rule

Sequence of OPERATIONS:
1. Measuring
2. Marking
3. Punching
4. Sawing/Cutting
5. Filling
6. Finishing
7. Inspecting

PROCEDURE:
1. The given mild steel flat piece is checked for given dimensions.
2. One edge of given is filed to straightness with rough and smooth files and checked with try
Square.
3. An adjacent is also filed such that is square to first edge and checked with try square.
4. Wet chalk is applied on one side of the flat and dried for making.
5. Lines are marked according to given figure, using odd leg caliper and steel rule.
6. Using the dot punch indentations are made along the marked lines.
7. The excess materials removed from the remaining two edges with try square level up to half of
the marked dots.
8. Finally burrs are removed by the filling on the surface of the fitted job.

PRECAUTIONS:
(1) Keep hands free from dirt oil and grease to avoid slip during work
(2) Do not carry sharp tool in pocket.
(3) Wear leather shoes all the time during work.
(4) Apply force only in forward stroke and relieve the force in backward stroke while
sawing and filing.
(5) While cutting hacksaw blade should remain straight to avoid any damage
(6) Do not hold work piece in hand during cutting
(7) Use file and hacksaw with properly fitted handle.
(8) After filing remove the burr from the edges of the work with brush, to prevent cuts to
the finger.
(9) Filing should be done with proper pressure of hand
(10) The perpendicularity of face ends edges is checked perfectly by using try square.
(11) Finishing is given by using only with smooth files.
(12) Marking is done without parallax error.
(13) Burrs on the edges should not be removed with hand to avoid cuts.

RESULT: The Square Fit is done successfully as per given specifications.

JOB DIAGRAM
 V-FITTING
EXPERIMENT NO: DATE: / / 20

AIM OF THE EXPERIMENT: To make a V-Fit from the given mild steel pieces with
specified dimensions.
MATERIALS REQUIRED: Mild steel flat (48 X 48 X 5mm).

TOOLS AND EQUIPMENT REQUIRED:

1. 6” try square
2. 6” scriber
3. Odd leg caliper
4. 12” hack saw Frame.
5. Blades (12 TPI)
6. 10” rough file
7. 10” smooth file
8. 10” Square file
9. Dot punch
10. Ball Pien Hammer
11. Steel Rule

Sequence of OPERATIONS:
1. Measuring
2. Marking
3. Punching
4. Sawing/Cutting
5. Filling
6. Finishing
7. Inspecting

PROCEDURE:
1. The given mild steel flat piece is checked for given dimensions.
2. One edge of given is filed with rough and smooth files and checked with try square for
straightness.
3. An adjacent edge is also filed such that it is square to first edge and checked with try square.
4. Wet chalk is applied on one side of the flat and dried for marking.
5. Lines are marked according to given figure, using odd leg caliper and steel rule.
6. Using the dot punch, indentations are made along the marked lines.
7. The excess materials removed from the remaining two edges with try square level up to half of
the marked dots.
8. Finally burrs are removed by the filling on the surface of the fitted job.

PRECAUTIONS:
(1) Keep hands free from dirt oil and grease to avoid slip during work
(2) Do not carry sharp tool in pocket.
(3) Wear leather shoes all the time during work.
(4) Apply force only in forward stroke and relieve the force in backward stroke while
sawing and filing.
(5) While cutting hacksaw blade should remain straight to avoid any damage
(6) Do not hold work piece in hand during cutting
(7) Use file and hacksaw with properly fitted handle.
(8) After filing remove the burr from the edges of the work with brush, to prevent cuts to
the finger.
(9) Filing should be done with proper pressure of hand
(10) The perpendicularity of face ends edges is checked perfectly by using try square.
(11) Finishing is given by using only with smooth files.
(12) Marking is done without parallax error.
(13) Burrs on the edges should not be removed with hand to avoid cuts.

RESULT: The V-fit is done successfully as per given specifications.

JOB DIAGRAM