VNU EUS EEC eE EEE eee eee Engineeri gineering Work Shop Department of Mechanical Engineering FITTING ‘The term fitting, is related to assembly of parts, after bringing the dimension or shape to . the i i i i Tequired size or form, in order to secure the necessary fit. The operations required for the ‘same are usually carried out on a work bench, hence the term bench work is also added with the name fitting, The bench work and fitting plays an important role in engineering. Although in today's industries most of the work is done by automatic machines which produces the jobs with good accuracy but still it (job) requires some hand operations called fitting operations. The person working in the fitting ‘shop is called fitter FITTING TOOLS: Fitting shop tools are classified as below: * Work Holding Devices/ Clamping Tools. * Measuring and Marking Tools. © Cutting Tools. * Striking Tools. * Drilling Tools. © Threading Tools. I. WORK HOLDING DEVICES /CLAMPING TOOLS: 1. Work Bench 'A fitting process can be done at various places, but most of the important operations of fitting are generally carried out on a table called work bench. ‘The work bench is a strong, heavy and rigid table made up of hard wood. ‘The size of the work bench required is about 150 to 180 cm length, nearly 90 cm width and approximately 76 to 84 cm height. 1[PageINSIDE CALIPER,Se ee ee ee ee Engineering Work Shop Department of Mechanical Engineering 2, BENCH VICE: Iris firmly fixed to the bench with the help of nuts and bolts. It consists of a cast fron body and cast iron jaws. Two jaw plates are fitted on both the jaws, The holding surface of the jaw plates i it ar is knurled in order to increase the gipping. Jaw plates are made up of carbon steel and are we: resistant. One jaw is fixed to the body and the second slides on a square threaded screw with the help of a handle, The jaws are opened upto required length; job is placed in the two jaws and is fully tightened with the help of handle. Handle is used to move the movable jaw 3. V Block In V Block, V grooves are provided to hold the round objects longitudinally. The screw of the clamp applies the holding pressure. When the handle is rotated there is movement in the screw Il. MEASURING TOOLS 1. Steel Rule These are made up of stainless steel and are available in many sizes ranging from 1/2 fi. to 2 ft. These are marked in inches or millimetres. All the faces are machined tue. The edges of steel rule should be protected from rough handling, 2. Calipers These are generally used to measure the inside or outside diameters, Different types are: i, Outside Calip : It is used 10 measure the outside dimensions. ii, Inside Caliper: It is used to measure the inside dimensions. ii, Spring Caliper: Spring is provided to apply the Pressure and lock nut is provided to lock any desited position. + iv. Hermaphrodite, Jenny OF Oddleg Caliper: One leg is bent at the tip inwardly and the other has a straight pointed end. 1tis used to scribe lines parallel to the straight edges.~TRY SQUARE SURFACE PLATE BALL PEEN HamerEngineering Work ingineering Work Shop Department of Mechanical Engineering 3. Vernier Caliper: It i ‘ernier Caliper: It is used for measuring the outer dimensions of round, flat, square components and also the inner size of the holes and bore. A narrow blade is used to measure the depth of bar lots etc. The reading accuracy in metric system is 0.02 mm and British system it is 0.001", It is made of stainless steel. I. MARKING TOOL! _ 1. Surface Plate It is used for testing the flatness, trueness of the surfaces. It is made up of cast iron or graphite. Its upper face is planed to form a very smooth surface. It is also used in scribing work, While not in use, it should be covered with a wooden cover. 2. Angle Plate It is made up of cast iron in different sizes; it has two-planied surfaces at right angles to each other and has various slots in edgh surface to hold the work by means of bolts and clamps. Never do hammering on the anglw plate to fasten (lighten) the nuts and bolts, 3. Scriber and Surface Gauge It consists 6f'a cast iron bass on the center of which a steel rod is fixed vertically. Scriber is made up of high carbon steel and is hardened from the front edge. Itis used for locating the centres of round bars or for marking of the lines. 4, Punches Punches are used for marking purposes. Dot punches are used for marking dotted line and centre punch is used to mark the centre 6f hole before drilling. Punches are made up of high carbon steel or high speed steels. One end is sharpened. Hammering is done on the second end while working. For dot punch, angle of the punching end is 60 degree while in centre punch; angle of punching end is 90 degree. 5, Try Square It is used for checking squareness of two surfaces. It consists ofa blade made up of steel, which is attached to a base at 90 degree. The base is made up of cast iron or steel. It isEngineering Work Shop Department of Mechanical Engineering IV. CUTTING TOOLS 1. Hacksaw Hacksaw ii used for cutting of rods, bars, pipes, flats etc. It consists of a frame, which is made from mild steel. The blade is placed inside the frame and is ightened with the help of a flange nut. The blade is made up of high carbon stcel or high speed stecl. . The points of the teeth are bent in a zig-zag fashion, to cut a wide groove and prevent the body of the blade from rubbing or jamming in the saw cut. The teeth of the blades are generally forward cut so in the case, pressure is applied in the forward direction only. Depending upon the direction of cut, blades are classified as: © Forward cut © Backward cut. Depending upon the pitch of the teeth (Distance between the two consecutive teeth) blades is classified as: © Coarse (8-14 teeth per Inch) © Medium (16-20 teeth per inch) Fine (24-32 teeth per inch) 2. Files Files are multi points cutting tools. It is used to remove the material by rubbing it on the metals. Files are available in a number of sizes, shapes and degree of coarseness. Classification of files On the basis of length 4",6",8",12" ii, On the basis of grade: © Rough (R)(20 teeth per inch) + Bastard (B)(30 teeth per inch)—_--BACKSAW-Engineering Work Shop Department of Mechanical Engineering © Second cut (Sc) (40 teeth per inch) © Smooth file ($)(50 teeth per inch) * Dead smooth (DS)(100 teeth per inch) Rough and bastard files are the big cut files. When the material removal is more, these files are used. These files have bigger cut but the surface produced Is rough. Dead smooth and smooth files have smaller teeth and used for finishing work. Second cut file has degree of finish in between bastard and smooth file. iii. On the basis of number of cuts: * single cut files. * Double cut files. * Rasp files. In single cut files the teeth are cut in parallel rows at an angle of 60 degree to the face. Another row of teeth is added in opposite direction in case of double cut files. Material removal is more in case of double cut files. iv. On the basis of shape and size: The length of the files varies from 4' to 14*. The various shapes of cross-section available are hand file, flat file, triangular, round; square, half round, knife-edge, pillar, needle and mill file. a. Flat file: This file has parallel edges for’about two-thirds of the length and then it tapers in width and thickness. The faces are double cut while the edges are single cut. b. Hand file: for-a hand file the width is constant throughout, but the thickness tapers as given in flat file. Both faces are double cut and one edge is single cut, The remaining edge is kept uncut in order to use for filing a right-angled corner on one side only. c. Square file: It has a square cross-section, It is parallel for two-thirds of its length and then tapers towards the tip. It is double cut on all sides, It is used for filing square corners and slots.FLAT FILE HAND Fe SQUARE Fite ULAR FILE A ROUND FILE HALF ROOND FILE KNIFE EDGE FILEOl DE OS ON wee Swe Engineering Work Shop Department of Mechanical Engineering Triangular file: It has width either parallel throughout or upto middle and then taperpd towards the tip, Its section is triangular (equilateral) and the three faces are double cut and the edges single cut, It is used for filing square shoulders or comers and for sharpening wood working saws. Round file: It has round cros s single cut teeth all round its surface. It is normally made tapered towards the tip and is frequently known as rat-tail file. Parallel round files having same diameter throughout the length are also available. The round files are used for opening out holes, producing round comers, round-ended slots ete. Nalf-round file: Its cross-section is not a true half circle but is only about one-third of a circle. The width of the file is either parallel throughout or upto middle and then tapered towards the tip. The flat side of this file is always a double cut and curved side has single Cut. It is used for filing curved surfaces, Knife edge file: It has a width tapered like a knife blade and it is also tapered towards the tip and thickness. It carries double cut teeth on the two broad faces and single cut teeth on the edge. It is used for finishing sharp corners of grooves and slots Diamond file: Its cross-section is like a diamond, It is used for special work. Needle file: These are thin small files having a parallel tang and a thin, narrow and pointed blade made in different shapes of its cross-section to suit the particular need of the work. These are available in sizes from 100 mm to 200 mm of various shapes and cuts. These files are used for filing very thin and delicate work. Methods of filing The following are the two commonly used methods of filing: 1 Cross-filing 2. Draw filing. Cross - filing. Refer Fig, (a). ‘This method is used for efficient removal of maximum amount of metal in the shortest possible time. It may be noted that the file must remain horizontal throughout the stroke (long, steady) with pressure only applied on the forward motion, slow andEngineering Work Shop Department of Mechanical Engineering Draw filing. Refer Fig. (b) This method is used to remove file Marks and for finishing operations. Here, the file is gripped as close to the work as possible between two hands. In this filing method, a fine cut file with a flat face should be used. FILE CARD: It is a device fashioned like a wire brush used to clean dirt and chips from the teeth of a file, When particles of metal clog the teeth the file is said to the pinned, a condition that causes seratching of the surface of the work. Files, therefore, require cleaning by means ofa file card or by dislodging the material between the teeth by means of a piece of soft iron, copper, brass, tin plate and so on, sharpened at the end. Hardened steel should never be used Hammers Hammersare used to strike a job or a tool. They are made of forged steel of various weights and shapes. ‘A hammer consists of four parts namely peen, head, eye and face. Hammers eras ball peen, cross peen and are classified according to the shape of the pe straight peen hammer.Commenced on: | Finished on. : | / 63 4S All dimensions are in mm. Seale i:) Tolerance = 0.SmmEX. NO:-1 SURFACE FILING AIM To get practice in surface filing, OPRATIONS TO BE CARRIED.OUT Cutting, measuring, holding, filing, and checking. * TOOLS REQURED Hack saw, steel rule, bench vice. and flat file. MATERIALS REQURED MLS flat of size 65*50*6 mm. PROCEDURE 1. ‘Cut the work piece with required dimensions using hacksaw. 2. Hold the work piece on the bench vice as one surface is in‘upward direction over the vice jaws 3. File the surface using a flat file ( Longitudinal filing) . 4. Check the straightness by using steel rule in lengthwise, width wise and diagonals. - _ §, Use smooth file at the finishing stage. ae 6. Finally finished the job and submit.EX. NO:-2 SIDE FILING Commenced on: Finished on | : -—————____ 63 4% T All dimensions are in mm. Seale 1: Tolerance = 0.5mmEX. NO:-2 SIDE FILING AIM To get practice in side filing. E 7 OFRATIONS TO BE CARRIED OUT ~~ Holding, filing, and checking. TOOLS REQURED. Bench vice, flat file, steel rule, and try square. "" MATERIALS REQURED “MS flat work piece of the previous exercise. } PROCEDURE i | 1. Take the work piece of the previous exercise. 2, Hold the work piece on the bench vice as one long side is in upward direction over the vice jaws 4 3. File this side using a flat file ( Transverse filing) up to the comer became sharp 4, Check the straightness by using steel rule, and also check the squareness to the filed surface with the help of a try square. 5. File the adjacent side and make it straight, right angle to the first side and also the filed surface. . 6. Finally finished the job and submit.° EX.NO;=3 MARKING & PUNCHING Commenced on: Finished on 24 corneas | me t Scale . 1:1 Tolerance + 0.5mm All dimensions are in mm.ag er EX. NO:-3 MARKING & PUNCHING AIM if To get practice in marking and punching, with the given dimensioned "L" shaped figure. OPERATIONS TO BE CARRIED OUT Chalk applying, marking, measuring and punching. . TOOLS REQUIRED Steel rule, surface plate, surface gauge, V- block, dot punch, ball peen hammer and anvil. MATERIALS REQUIRED MS flat work piece of the previous exercise and chalk piece. PROCEDURE 1. Take the work piece of the previous exercise. 2. Apply thin coating of chalk paste on the filed surface and allow it to dry. 3. Place the work-piece on the surface plate supported with.a V- block. a 4. Mark the required lines as per the drawing dimensions using surface gauge and steel rule. .-5. Check the marked lines with,steel rule. 6. Place the work piece on the anvil and punch the required lines with about 3mm gap using dot’ ~ punch and ball peen hammer. 7. Finally finish the job and submit.EX. NO:-4 'L’ CUTTING Commenced on: 2b Finished on 60 All dimensions are in mm.” Scale. |:1 ° i lerance + 0.5mmXNO:-4 ‘L! CUTTING 7 To get practice in "L"cutting. OPERATIONS TO BE CARRIED OUT ; Holding, cutting, filing and checking. FOOLS REQUIRED . i Bench vice, hacksaw, flat file ( Rough and Smooth), triangular file. square file. try square and steel rule. \ MATERIALS REQUIRED t MS flat work piece with "L" shape punched lines ofthe previous exercise. PROCEDURE TI. Take the work piece of the previous. exercise. 2. Hold the work piece ‘on the bench vice and first make the hacksaw cutting straightly by using a hacksaw. 3. Cut the unwanted portions using hacksaw. . 4. Remove the excess metals by filing with suitable files on proper place. 5. Check the dimensions, finish the job and submit.