DEPARTMENT OF MECHANICAL ENGINEERING

WORKSHOP: ME – 192/292

FITTING
 FITTING
Fitting is related to assembly of parts, after bringing the dimension or shape to the required 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.

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.

2. BENCH VICE:
It is firmly fixed to the bench with the help of nuts and bolts. It consists of a cast Iron body and
cast iron jaws. Two jaw plates are fitted on both the jaws. The holding surface of the jaw plates is
knurled in order to increase the gripping. Jaw plates are made up of carbon steel and are wear
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 up to 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.

MEASURING TOOLS

1. STEEL RULE:
These are made up of stainless steel and are available in many sizes ranging from 1/2 ft. to 1 ft.
These are marked in inches or millimeters. All the faces are machined true. 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 CALIPER: It is used to measure the outside dimensions.

ii. INSIDE CALIPER: It is used to measure the inside dimensions.
iii. ODD LEG CALIPER: One leg is bent at the tip inwardly and the other has a straight pointed
end. It is used to scribe lines parallel to the straight edges.

MARKING TOOLS:

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.

ANGLE PLATE:
It is made up of cast iron in different sizes; it has two planed surfaces at right angles to each
other and has various slots in each surface to hold the work by means of bolts and clamps. Never
do hammering on the angle plate to fasten (lighten) the nuts and bolts.
SCRIBER AND SURFACE GAUGE:
It consists of 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. It is used for locating the centers of
round bars or for marking of the lines.

PUNCHES:
Punches are used for marking purposes.

Prick Punches are used for marking purposes. Prick punches are used for marking dotted line and
centre punch is used to mark the centre of 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.

CENTER PUNCH PRICK PUNCH

For Prick punch, angle of the punching end is 60 degree

While in center punch; angle of punching end is 90 degree
Prick punches are used for marking dotted line and centre punch is used to mark the centre of 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.
TRY SQUARE:
It is used for checking squareness of two surfaces. It consists of a 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 also used to mark
the right angles and measuring straightness of surfaces. Never use try square as a hammer.

METHOD OF MARKING:
Marking means setting out dimensions with the help of a working drawing or directly transferring
them from a similar part. The procedure of marking is as follows:
1. The surface to be marked is coated with the paste of chalk or red lead and allowed to dry.
2. Then the work is held in a holding device depending upon shape and size. If it is flat, use surface
plate, if it is round use V block and clamp, else use angle plate etc.
3. Lines in horizontal direction are scribed by means of a surface gauge. Lines at right angles can
be drawn by turning the work through 90 degree and then using the scriber. If true surface is
available, try square can also be used.
4. The center on the end of a round bar can be located by using an odd leg caliper, surface gauge
etc.
5. The circles and arcs on a flat surface are marked by means of a divider.
6. After the scribing work is over, indentations on the surface are made using dot punch and
hammer.

Depending upon the direction of cut, blades are classified as

1. Forward cut 2. 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)
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”

ON THE BASIS OF GRADE:

•Rough (R) (20 teeth per inch)
•Bastard (B) (30 teeth per inch)
•Second cut (Sc) (40 teeth per inch)
•Smooth file (S) (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.

ON THE BASIS OF NUMBER OF CUTS:

•Single cut files. •Double cut 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.
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.
d. ROUND FILE:
It has round cross-section. It carries 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 etc.
e. HALF-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 up to 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.
f. TRIANGULAR FILE:
It has width either parallel throughout or up to middle and then tapered 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.
METHODS OF FILING:
The following are the two commonly used methods of filing:
1. Cross-filing 2. Draw filing.
CROSS-FILLING
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, slow and
steady) with pressure only applied on the forward motion
DRAW FILING
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.