STRAIGHT FITTING

Straight Fitting
 Straight Fitting
Aim: To make a Straight Fitting.

Objective:
After performing the practical, the learner will be able to:
PRO 1. Know about the basics of fitting process.
PRO 2: Use of various tool and equipment for fitting process.
PRO 3: Know about the preventive measurements as followed in fitting shop.

Material : M. S. Flat of 105 x 50 x 6 mm.

Tools : Scale, Hacksaw, Flat file, Hand file, Try-square, Scriber, Punch,
Vernier Caliper, Hammer, Drills, Taps, Tap wrench, Chisel, Vernier height
gauge etc.

Theoretical background:
In workshop and manufacturing technology, there are several processes through which
components can be manufactured. We use machining, additive manufacturing, casting etc.
and many other technologies and processes to achieve desired components. These
components are manufactured on the shop floor and then assembled on the assembly lines.
However, the most important objective behind making these parts or components is to
achieve the desired fit during assembly for these manufactured components. With proper
fitting, these components and the processes used on them are a waste as the customer will
reject a non-fitting assembly. The component used in drawing shown below is an example
for our students to make the assembly fitting and understand the importance of the same.

Procedure:
1. Read and understand the theory of fitting process mentioned in the journal.
2. Listen to and understand the explanation from instructor.
3. Take the M. S. Flat of 105 x 50 x 6 mm size and hold it in Bench vice.
4. File one face to perfect level with help of flat file and check level by using try-
square.
5. File one long and short side mutually right angle to each other and to the face.
6. File second short side and maintain it size with parallelism.
7. Apply wet chalk on the face and do marking as per diagram with help of Vernier
height gauge.
8. Take part ‘A’ and clamp it in machine vice.
9. Drill the hole of 4 mm size as per diagram which is called clearance hole.
10. Then take part ‘B’ and do the same as part ‘A’.
 11. Take part ‘A’ and remove extra material by sawing with help of hacksaw.
12. File extra material by using flat file, hand file & half round file.
13. File all sides of part ‘A’ with maintaining size.
14. Measure all dimension with help of Vernier caliper & maintain all the dimensions of
part ‘A’ as per given diagram by filing.
15. Then take part ‘B’ and remove extra material by sawing with help of hacksaw.
16. Do the filing & maintain all the dimensions of part ‘B’ as per given diagram.
17. After filling check the fit with help of part ‘A’, if it is not maintaining then file the
high spots by using smooth file.
18. Check the fit constantly with part ‘A’ by using it as a gauge.
19. Finish outer surface with smooth file.
20. Remove burr and stamp roll no. on both the pieces.
21. Fit part ‘A’ and part ‘B’ and submit the job for inspection.

Precaution:
1. Do not use broken handle file and hammer.
2. Use measuring tools carefully.
3. Position the job close to the vice jaw to prevent springing, saw breakage &
personnel injury.
4. Apply force only on the forward stroke while cutting.

Result and analysis:______________________________________________________

_______________________________________________________________________
_______________________________________________________________________

Objective PRO 1 PRO 2 PRO 3

Total
Weight 20 20 20 Score H&S DEPARTMENT STAMP
Points

Score

Earned Points (EP) = Total Score / 60 = Marks in 100 = EP*20 =

INTERNAL THREADING ON PIPE
 Internal Threading on Pipe

Aim: To make internal threading on pipe.

Objective: After performing the practical, the learner will be able to:
PRO1: Use scale, flat files, tap set and tap wrench
PRO2: Use round files properly
PRO3: Know the specific use of lubricating oil
Material:
¾” G. I. Pipe of 6” length.
Tools: Scale, Flat File, Tap Set, Tap Wrench, Round File, Oil Can etc.
Theoretical background:
Threading is the process of creating screw threads either on the surface or inside
the surface.
1. Scale:-It is made of stainless steel and is use for measuring the length of
the pipe and to make accurate marking where ever it is required.
2. Flat Files:-It is use to remove the amount of material from work piece. It
is made of case hardened steel bar. It can be of various shapes.
3. Tap wrench:-It is use to provide grip and applying torque to turn objects
such as nut and bolt.
4. Tap set:-It is the set of die and tap, used to create screw threads known as
threading. Many are cutting tools and others are forming tool. A tap is use
to cut or form threads in the inner surface of the work piece like nut. A die
is use to cut or form threads in the outer surface of the work piece like bolt.
5. Oil can: During thread making process lot of heat is generated due to
friction between the surfaces. In order to reduce the friction oil is use as
lubricant.
Procedure:
1. Take the ¾” G. I. Pipe of 6” lengths by measuring with scale
2. Do the filing on both the faces of pipe by using flat file & maintain
right angle with wall of pipe.
 3. Remove internal burr by using round file & external burr by using flat file.
4. Take the tap set of 5/8” BSP, 14 TPI & tap wrench.
5. Hold the first tap (Rougher) in the tap wrench.
6. Hold the pipe firmly in the pipe vice.
7. Do the marking of 40mm on the tap from bottom of tap.
8. Place the tap straight on the pipe hole & start the tapping by turning it
clockwise.
9. Once it gets start turn backward (anti-clockwise) half a rotation after each
rotation so that the chips are being broken.
10.When threads of sufficient length are made then the tap is screwed back &
removed.
11.Use plenty of lubricant.
12.Then take finishing tap & hold it in tap wrench.
13.Then do tapping same way as first tap & finish the internal thread on the pipe.
14.After completing internal threading, remove the tap.
Precaution: -
1. Do not apply excess pressure on the tap while tapping.
2. Clean the tap before tapping.
Result and analysis:______________________________________________________
_______________________________________________________________________
_______________________________________________________________________

Objective PRO 1 PRO 2 PRO 3

Total
Weight 20 20 20 Score H&S DEPARTMENT STAMP
Points

Score

Earned Points (EP) = Total Score / 60 = Marks in 100 = EP*20 =

EXTERNAL THREADING ON PIPE
 External Threading on Pipe

Aim: To make external threading on pipe.

Objective:
After performing the practical, the learner will be able to:
PRO1: Use flat file and spanner
PRO2: Know the specific use of die-piece and die stock
PRO3: Use of tri-squares
PRO4: Use of lubricating oil

Material:
½” G. I. Pipe of 6” length.

Tool:
Scale, Flat File, Try Square, Die-Piece, Die Stock, Spanner, Oil Can etc.
Theoretical background:
Threads on pipe play an important role during connection. Two pipes or any
other device can be connected together by using threads. These can be of various
shapes depending upon the forces and place of uses.
1. Scale: - It is made of stainless steel and is use for measuring the length of
the pipe and to make accurate marking where ever required.
2. Flat Files: - It is used to remove the amount of material from work piece.
It is made of case sharpened steel bar.
3. Dies and dies stock: Dies are cutting tools that produce external screw
thread, also known as male screw threads. It is used along with die stocks,
which are tools that hold round and hex dies to ensure proper alignment
and uniform threads.
4. Try square: - It’s a wooden or metal working tool used for marking and
measuring the work piece The square refers to the tool’s primary use of
measuring the accuracy of a right angle and to check its straightness or
correspondence to an adjoining surface.
5. Spanner: It is also known as wrench. It is used to provide grip and
applying torque to turn objects such as nut and bolt.
 Procedure for making external threading on the pipe
1. Take the ½” G. I. Pipe of 6” length by measuring with scale.
2. Do filing on both the faces of pipe with flat file and maintain right angle with
wall of pipe.
3. Do chamfering on both end of pipe of 2mm x 45.
4. Take the die piece of ½” BSP, 14 TPI & die stock.
5. Set the Die piece into the die stock & lock it by locking cap.
6. Hold the pipe firmly in the pipe vice.
7. Do the marking of 40mm from the chamfer end.
8. Set the die on pipe & start the die by rotating it in clockwise direction.
9. Once it gets start turn backward half a rotation after each rotation so that the
chips are being broken.
10.When sufficient length of thread has been made to measure the accuracy by
using try square.
11.Then give the depth by tightening set screw & repeat same process.
12.Use plenty of lubricating oil
Precaution: -
1. While setting die piece set it equally.
2. Clean the die piece & die stock before using it.
3. Use brush for cleaning the die stock.

Result and analysis:______________________________________________________

_______________________________________________________________________
_______________________________________________________________________

Objective PRO 1 PRO 2 PRO 3 PRO 4

Total
Weight 20 20 20 20 Score H&S DEPARTMENT STAMP
Points

Score

Earned Points (EP) = Total Score / 80 = Marks in 100 = EP*20 =

WOODEN TRAY
 Wooden Tray
Aim: To make Wooden Tray
Objective: After performing the practical, the learner will be able to:
PRO1: Use the handsaw for cutting wooden block
PRO2: Use of metal jack planner
PRO3: Know about marking gauge and other measuring devices
PRO 4: Know about the firmer chisel, scriber and fevicol
PRO5: Use of rasp cut file and varnish
Material: 2” x ½” Teakwood, 12” x 9” Plywood of 6mm thick.
Tools: Scale, Handsaw, Metal Jack Planner, Marking Gauge, Firmer Chisel,
Scriber, Hammer, and Rasp cut file etc.
Theoretical background: Wooden tray is use for serve placed item. It can be
placed on the table. During making Wooden Tray learner will learns about the
various carpentry tools and processes.
1. Hand saws: In carpentry hand saws is also known as “panel saws”, are
used to cut pieces of wood into different shapes. This is usually done in
order to join the pieces together and crave a wooden object.
2. Metal jack planner: It is a general purpose carpentry bench plane use
for dressing timber down to the correct size in preparation for truing edge
jointing.
3. Marking gauge: It is also known as “scratch gauge”, it is used to mark
out lines for cutting or other operations. The purpose of the gauge is to
scribe a line parallel to a reference edge.
4. Scriber: It is a hand tool used in carpentry to make lines on work pieces,
prior to machining.
5. Firmer chisel: It is one of the types of carpentry chisel use for specific
purpose, it has a blade with a thick rectangular cross section, making
them stronger for use on tougher and heavier work.
 Procedure :-
1. Use the handsaw for cutting wooden block
2. Initially cut all the wooden piece of wooden tray as per the given size by using
handsaw.
3. Perform planning operation by using metal jack planner.
4. Do the planning operation by using metal jack planner & maintain all the pieces as
per given size.
5. Know about marking gauge and other measuring devices
6. Do the marking on part A & B as per the given diagram by using try square,
marking gauge, scale & pencil.
7. Cut 6 x 12 mm step on part A by using firmer chisel & handsaw.
8. Assemble part A & B as per given diagram by using fevicol, vinels & hammer.
9. Then cut plywood as per base size by using handsaw.
10. Plain the two sides of it and make 90º with each other.
11. Fix plywood on bottom side of frame by using fevicol, vinels & hammer.
12. Do the finishing of wooden tray with the help of Rasp cut file & wooden polish
paper.
13. At the end perform wornishing operation as per instructions.
14. Then stamp the Roll No. on job & submit it for inspection.
Precaution: -
1. When sawing does not apply to much pressure and use correct speed.
2. Mark dimensions properly & carefully as per given diagram.
Result and analysis:______________________________________________________
_______________________________________________________________________
_______________________________________________________________________

Objective PRO 1 PRO 2 PRO 3 PRO 4 PRO 5

Total
Weight 20 20 20 20 20 Score H&S DEPARTMENT
STAMP
Points

Score

Earned Points (EP) = Total Score / 100 = Marks in 100 = EP*20 =

WOODEN ROLLER
 Wooden Roller

Aim: To make wooden roller.

Objective:
After performing the practical, the learner will be able to:
PRO1: Use of scale and other measuring & marking devices.
PRO2: Learn the use of metal jack planner.
PRO3: Learn the use of wood turning tool like firmer chisel & use of outside caliper.
PRO4: Know the uses of various wood turning tools.
PRO5: Learn the use of rasp cut file & sand paper.
Material: 1½” x 1½” x 14” Teak wood.
Tools: Scale, Handsaw, Rasp cut file, Metal Jack Planner, Hammer, Outside calliper,
Measuring Tape, Wood Turning Tool set etc.
Theoretical background:
1. Scale: It is made of stainless steel and is use for measuring the length of the pipe
and to make accurate marking where ever its required.
2. Metal jack planner: It is a general purpose carpentry bench plane use for dressing
timber down to the correct size in preparation for truing edge jointing.
3. Wood turning tool: It is a hand held tool used to cut a shape that is symmetrical
around the axis of rotation
4. Outside calliper: A calliper whose legs turn inward so that it can measure the
outside dimensions, as the diameter of rod.
5. Measuring Tape: It is a flexible ruler used to measure distance. It consists of
ribbon of cloth or metal strip with linear measurement markings.
6. Hand saws: In carpentry hand saws is also known as “panel saws”, are used to cut
pieces of wood into different shapes. This is usually done in order to join the pieces
together and crave a wooden object.
7. Hammer: It is a device that delivers a sudden impact to an object. Hammers vary
in shape, size and structure depending upon their purpose. These are usually made
of steel.
8. Rasp cut file: It is a form of file with distinct, individually cut teeth used for
coarsely removing large amount of material from a work piece.
 Procedure: -
1. Measure and mark all the dimensions on the work piece by using scale
2. Find out center of face and mark circle of diameter 30 mm on the job.
3. Plane the four edges of the job by using jack planner.
4. Firmly hold the job on the wood turning machine in between centers.
5. First, use firmer chisel & do plane turning and maintain the diameter of wood
is 30 mm.
6. Check the parallelism with help of outside calliper.
7. Then do marking as per diagram.
8. Do step of Ø20 x 65 mm on both the end of job as per diagram.
9. Do the taper turning by using parting tool as per diagram.
10.Do radius on both the end of R-3 by using gauge as per diagram.
11.Then use sand paper for smoothness.
12.Remove job from lathe machine and Saw off extra material & smoothen
corners by rasp cut file.
Precaution: -
1. Do not ware loose cloth while working on machine.
2. Hold the job firmly on the machine.
3. Do not use cutting tool without handle.
Result and analysis:______________________________________________________
_______________________________________________________________________
_______________________________________________________________________

Objective PRO 1 PRO 2 PRO 3 PRO 4 PRO 5

Total
Weight 20 20 20 20 20 Score H&S DEPARTMENT
STAMP
Points

Score

Earned Points (EP) = Total Score / 100 = Marks in 100 = EP*20 =

Butt Joint By Arc Welding
 Butt Joint By Arc Welding
Aim: To make Butt Joint by Arc Welding
Objective: After performing the practical, the learner will be able to:
PRO1: Use of scale, hacksaw, files
PRO2: Know and practice how to use welding machine and its various
components.
PRO3: Know about the use of cleaning tools like chipping hammer wire brush etc.
PRO4: Know the specific use of oil can, welding screen and flat tong
Material: M.S. Plate of 100 x 50 x 6 mm, M.S. Electrode Ø 2.5 mm.
Tools: Scale, Try Square, Hacksaw, Wire Brush, Welding Screen, Flat Tong,
Gloves, Chipping Hammer, File & Welding M/C(Transformer) Etc.
Theoretical background:
1. Scale: It is made of stainless steel and is use for measuring the length of the
pipe and to make accurate marking where it is requiring.
2. Hacksaws: In welding hacksaw is use for cutting work pieces of metal into
different sizes. It has fine toothed blade combined with C-shaped frame that
hold it under tension.
3. Try square: - It’s a wooden or metal working tool used for marking and
measuring the work piece The square refers to the tool’s primary use of
measuring the accuracy of a right angle, to try surface is to check its
straightness or correspondence to an adjoining surface.
4. Welding machine transformer: It is use to transform the power supply from
moderate voltage and current into a high current and low voltage supply.
5. Chipping hammer: It is use to remove the extra material or spatter from the
weld surface.
6. Wire brush: It is a brush consisting of wire bristles usually of medium carbon
steel. It is use to clean surfaces and to create a better conductive area for
electricity.
 7. Welding screen: It is use by the welders during performing welding. It protects the
eyes from the harmful UV rays generating from the welding torch.
8. Flat tong: It is use to hold and lift the work piece instead of holding them directly
with hands.
9. Gloves: It is use during welding because they protect our hands against any sort of
contact with heat or mechanical aggression. Its main role is to protect from the
molten metal and heat given off by welding gun.
Procedure: -
1. Take the M.S. plate of 100 x 50 x 6 mm dimension by using scale.
2. Cut the 2 pieces of 50 mm with hacksaw.
3. Hold the one piece of plate in a vice & prepare all edges to 90 with filling.
4. Repeat same operation for the remaining plats & maintain it in equal size.
5. Remove burr of all edges.
6. Take two plates, set the ‘Butt’ joint as per show in dig.
7. Start the welding machine & set the current 70 amps.
8. Take the electrode Ø 2.5mm & hold it in the electrode holder.
9. Do tag weld at the corner of joint.
10. Welding is then carried out throughout the length of the Butt joint
11. Clean the tag weld with help of chipping hammer & wire brush.
12. Use welding screen and flat tong as a safety instrument during welding process.
Precaution: -
1. Use the tong for lifting hot job.
2. Use welding screen, hand gloves while welding.
Result and analysis:______________________________________________________
_______________________________________________________________________
_______________________________________________________________________

Objective PRO 1 PRO 2 PRO 3 PRO 4

Total
Weight 20 20 20 20 Score H&S DEPARTMENT STAMP
Points

Score

Earned Points (EP) = Total Score / 80 = Marks in 100 = EP*20 =

Butt Joint By Gas Welding
 Butt Joint By Gas Welding

Aim: To make Butt Joint by Gas Welding

Objective: After performing the practical, the learner will be able to:
PRO1: Use of scale, hacksaw, files
PRO2: Know and practice how to use Gas welding Equipment and its various
components.
PRO3: Know about the use of cleaning tools like chipping hammer wire brush etc.
PRO4: Know the specific use of oil can, welding Goggle and flat tong
Material: M.S. Plate of 100 x 50 x 2 mm, C.C.M.S. Electrode Ø 1.6 mm.
Tools: Scale, Try Square, Hacksaw, Wire Brush, Welding Goggle, Flat Tong, Hand
gloves, Chipping Hammer, File & Oxy – acetylene welding outfit, Etc.
Theoretical background:
1. Scale: It is made of stainless steel and is use for measuring the length of the
pipe and to make accurate marking where it is required.
2. Hacksaws: In welding hacksaw is use for cutting work pieces of metal into
different sizes. It has fine toothed blade combined with C-shaped frame that
hold it under tension.
3. Try square: - It’s a wooden or metal working tool used for marking and
measuring the work piece The square refers to the tool’s primary use of
measuring the accuracy of a right angle , to try surface is to check its
straightness or correspondence to an adjoining surface.
4. Chipping hammer: It is use to remove the extra material or spatter from the
weld surface.
5. Wire brush: It is a brush consisting of wire bristles usually of medium carbon
steel. It is use to clean surfaces and to create a better conductive area for
electricity
6. Welding Goggle: It is use by the welders during performing welding. It
protects the eyes from the harmful UV rays generating from the welding torch.
 7. Flat tong: It is use to hold and lift the work piece instead of holding them
directly with hands.
8. Gloves: It is use during welding because they protect our hands against any
sort of contact with heat or mechanical aggression. The main role is to protect
from the molten metal and heat given off by welding gun.
Procedure: -
1. Take the M.S. plate of 100 x 50 x 2 mm dimension by using scale.
2. Cut the 2 pieces of 50 mm with hacksaw.
3. Hold the one piece of plate in a vice & prepare all edges to 90 with filling.
4. Repeat same operation for the remaining plat & maintain it in equal size.
5. Remove burr of all edges.
6. The given work piece is thoroughly cleaned, i.e., rust, scales are removed
7. The joining work pieces are positioned properly.
8. Acetylene valve on the torch is opened slightly and lightened with the help of a
spark lighter.
9. Now acetylene valve is opened to get required the flow of acetylene.
10.Oxygen valve is opened till the intermediate flame feather reduces into inner
cone to get a neutral flame.
11.The torch tip is to be positioned above the plates so that white cone is at a
distance of 1.5mm to 3mm from the plates.
12.Torch is to be held at an angle of 300 to 450 to the horizontal plane.
13.Now filler rod is to be held at a distance of 10mm from the flame and 1.5 mm
to 3 mm from the surface of the weld pool.
14.As the backward welding allows better penetration, back ward welding is to be
used.
 15.After the completion of welding, slag is to be removed by means of chipping
Hammer, wire brush.
16.Use welding Goggle and flat tong as a safety instrument during welding
process.
Precaution: -
1. Use the tong for lifting hot job.
2. Use welding goggle, hand gloves while welding.
Result and analysis:______________________________________________________
_______________________________________________________________________
_______________________________________________________________________

Objective PRO 1 PRO 2 PRO 3 PRO 4

Total
Weight 20 20 20 20 Score H&S DEPARTMENT STAMP
Points

Score

Earned Points (EP) = Total Score / 80 = Marks in 100 = EP*20 =