TOPIC FIVE

FITTING SHOP

5.1 Preamble

These days small, medium and heavy industries are using automatic machines. But bench and
fitting work also plays a significant role for completing and finishing a job to the desired
accuracy. Most of semi-finished works can be accomplished with fairly good degree of
accuracy in a reasonable time through various kinds of quick machining operations. They still
require some minor operations to be performed to finish the job by hand.
The term 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 craftsman that works in the fitting shop is known as a fitter.

5.2 Why using hand tools

"Man without tools is nothing; with tools he is all”. This sentence, which was defined by
Thomas Carlyle, has well elaborated the importance of tooling to a man. The term
'Tooling' as applied to the engineering discipline refers to any equipment or
instruments that give helps in the production of a product or any related activities. Simply
speaking, it ranges from the most fundamental type of hand tools, such as a File, to the
very complex machine tools, such as a CNC Machining Centre. Thus, one may ask the
question - Why we still have to use band tools in this modern age of technologies?

Yes, it is reasonable to say that the efficiency of any hand processes is low and the quality
of outcome depends highly upon the skill of individuals. Perhaps it is fair to consider the
following points before a definite answer is given to the above question:

5.2.1 Accuracy

Although the CNC machine can give a higher degree of dimensional accuracy when
compared with the inconsistent outcome of hand fitting, the extreme high degree of flatness
required for a surface table or a machine slideway is usually obtained by hand scraping only.
5.2.2 Flexibility

Hand processes are very flexible and can be carried out at any place necessarily while
machining processes cannot be. In addition, machining usually requires a rigid setting up,
while fitting is simple.

5.2.3 Quantity

For large batch size, advanced production machines are commonly employed in order to
maintain the accuracy as well as the efficiency, but for "jobbing type" works, such as
manufacturing of a prototype or repairing a single component, it would be uneconomic to
use these advanced machine tools. Instead, "jobbing type" works are usually produced
by conventional machining and followed by hand fitting necessarily.

5.2.4 Final Assembly

In the assembly of precise component parts, no matter how accurate they are being
produced, a skilful fitter is often required to give the necessary "finishing touch" on them to
ensure that everything goes together correctly.

5.3 Tools used in fitting shop

Bench work and fitting requires a large number of hand tools, one need to have a good
working knowledge of all these tools to carry out the finishing and assembling in more
effective and efficient manner. The tools are classified as follows:
1. Measuring tools
2. Marking tools
2. Cutting tools
3. Holding tools
4. Striking tools
5. Supporting tools, and
6. Miscellaneous tools

5.4 Measuring tools in workshop

5.4.1 Calipers
They are indirect measuring tools used to measure or transfer linear dimensions. These are
used with the help of a steel Rule to check inside and outside measurements. These are made
of Case hardened mild steel or hardened and tempered low carbon steel. While using, but the
legs of the caliper are set against the surface of the work, whether inside or outside and the
distance between the legs is measured with the help of a scale and the same can be transferred
to another desired place. These are specified by the length of the leg. In the case of outside
caliper, the legs are bent inwards and in the case of inside caliper, the legs bent outwards.
Calipers are the very simple tools used together with a steel rule for the measurement or
comparison of linear dimensions. An experienced worker can achieve +/-0.05mm in the
measurement (Fig. 5.1).

Fig 5.1 Calipers

Calipers are classified into two types:

5.4.1.1 Outside caliper

Outside caliper, as shown in Fig. 5.2, are used for measuring external dimensions such
as the length, diameter, or even the thickness of a solid.
 Fig. 5.2 Outside caliper

5.4.1.2 Inside caliper

Inside caliper as shown in Fig. 5 . 3, are used for measuring internal dimensions such
as the diameter of a hole, or the width of a slot, etc.

Fig. 5.3 Inside caliper

5.4.2 Vernier caliper

Vernier Calipers, as shown in Fig. 5.4, are the more precise tools that capable for
measuring external dimensions, internal dimensions, and depths. Besides, both pairs of
measuring jaws and the depth gauge have the main features that including a main
scale and a vernier scale.

Fig. 5.4 Vernier caliper

The resolution of a vernier scale is determined by the difference on the distance of one
division on the main scale and one division on the vernier as shown in Fig.5.5. For
example, a vernier scale of length 49mm is divided into 50 equal divisions. That means
ONE division on the vernier represents 49/50 = 0.98mm while ONE division on the main
scale represents 1mm. Then, the resolution of the vernier is 1mm - 0.98mm = 0.02mm.

Fig. 5.5 Vernier reading

5.4.3 Vernier height gauge

The Vernier Height gauge clamped with a scriber. It is used for layout work and offset scriber
is used when it is required to take measurement from the surface, on which the gauge is
standing. The accuracy and working principle of this gauge are the same as those of the
vernier calipers. Its size is specified by the maximum height that can be measured by it. It is
made of Nickel‐Chromium Steel (Fig. 5.6).

Fig 5.6 Vernier height guage

5.4.4 Micrometer

A micrometer is a more precise measuring instrument than the vernier caliper. The
accuracy is come from the fine thread on the screw spindle. The ratchet prevents excess
force from being applied. Generally, the screw spindle has a pitch of 0.5mm. The thimble
is divided into 50 equal divisions. Common types of micrometer used in the workshops
are: An outside micrometer, as shown in Fig. 5.7, is used for measuring external
dimensions. The work to be measured is placed between the anvil and the tip of the
spindle.

The structure of Inside micrometer is as similar as that of an outside micrometer. It is used

for measuring internal dimensions as shown in Fig. 5.8.

Fig. 5.7 Outside micrometer Fig. 5.8 Inside micrometer

5.4.5 Depth micrometer

A depth micrometer, as shown in Fig. 5.9, is used for measuring the depth of a hole, slot
and keyway, etc. A complete set of depth micrometer is equipped with spindles of
different lengths, which can be interchanged to suit different measuring ranges.

Fig. 5.9 Depth micrometer

5.4.6 Protractor

5.4.6.1 Engineer's Protractor

An engineer's protractor, as shown in Fig. 5.10, is a general purpose tool used for the
measuring / checking angles, e.g. the angle of drill head, angle of cutting tool, and even for the
marking out of angles on a component part.

5.4.6.2 Vernier Protractor

This is a precision measuring tool that the accuracy of measurement can reach ±5 minutes of
an angle through the vernier scale as shown in Fig. 5.11.

Fig. 5.10 Engineer's Protractor Fig. 5.11 Vernier Protractor

5.4.7 Combination Set

A combination set, as shown in Fig. 5.12, is a set of equipment combining the functions of
protractor, engineer square, steel rule, centre finder, level rule, and scriber.
 Fig. 5.12 Combination Set

5.4.8 Dial Indicator

A dial indicator (dial gauge) can measure dimensions up to an accuracy of 0.01mm or even
less. The principle of it is that the linear mechanical movement of the stylus is magnified
and transferred to the rotation of pointer as shown in Fig. 5.13. It is usually used as a
comparator for calibration or alignment of machine.

Fig. 5.13 Dial Indicator

5.4.9 Steel rule

It is the simplest measuring tool just like a scale used in fitting shop. The steel rule (Fig.5.14) is a
graduated strip of metal used to determine any required dimension within the scope of the
graduation. Steel rules are obtainable in various lengths and widths and graduated in centimeters
and millimeters. Also, there is a steel tape rule (which is a long narrow folding steel rule)
graduated and used in the same manner as steel rule, but for measuring long dimensions.

Fig 5.14 Steel rule

5.5 Marking out tools in workshop

Marking out is the preliminary work of providing guidance lines and centres before cutting
and machining. The lines are in 3-D and full-scale. The workpiece can then be cut or
machined to the required shape and size. The common tools used for marking out are as
follow:

5.5.1 Marking out table

All marking out processes are done on this table. It is made of cast iron. The purpose of marking
out is to provide a visual guide in the form of a scribe lines, so that the component can be made
to the sizes required.
5.5.2 Scriber

A scriber, as shown in Fig. 5.15, is used for scratching lines onto the workpiece. It is made of
hardened tool steel, which is hardened and tempered to a suitable hardness.

Fig. 5.15 Scriber

5.5.3 Engineer's square

Engineer's square, as shown in Fig. 5.16, is made of hardened tool steel. It is ground to a precise
squareness and straightness. It is not only used for checking the straightness and the
squareness of a workpiece, but it can also be used for marking parallel or perpendicular
lines onto a workpiece. The blade of the Try square is made of hardened steel and the stock of
cast Iron or steel. The size of the Try square is specified by the length of the blade.
 Fig. 516 Engineer's square

5.5.4 Spring dividers

Spring dividers, as shown in Fig. 5.17, are made of hardened tool steel. The legs are used for
scribing arcs or circles onto a workpiece.

Fig. 5.16 Spring divider

5.5.5 Punch

There are two types of punch named as the Centre Punch and the Dot Punch (Fig 5.17 and
Fig 5.18). A dot punch has a point angle of either 30 or 60 degrees, so it can be used for
marking small dots on the reference line. The centre punch has a point angle of 90 degrees as
shown in Fig. 5.17. It is used for making a large indent on a workpiece for drilling. Both
punches are made of hardened tool steel.

Fig 5.17 Dot Punch Fig 5.18 Center Punch

(a) Dot punch: It is used to lightly indent along the layout lines, to locate center of holes and to
provide a small center mark for divider point, etc. for this purpose, the punch is ground to a
conical point having 60° included angle.
(b) Center punch: is similar to the dot punch, except that it is ground to a conical point having
90° included angle. It is used to mark the location of the holes to be drilled.
5.5.6 Surface plate
Surface plate, as shown in Fig. 5.19, is made of malleable cast iron. It has been machined and
scraped to a high degree of flatness. The flat surface is being used as a datum surface for
marking out and measuring purposes. Large surface plate that can stand on the floor is known as
surface table. Surface plate is made of Cast Iron, hardened Steel or Granite stone. It is specified
by length, width, height and grade. Handles are provided on two opposite sides, to carry it while
shifting from one place to another.

Fig. 5.19 Surface Plate

5.5.7 Angle plate

An angle plate, as shown in Fig. 5.20, is used for supporting or setting up work vertically.
Slots and holes are provided for mounting and fixing the workpiece. It is made of cast iron and
ground to a high degree of accuracy.
 Fig. 5.20 Angle plate Fig. 5.21 Vee Block

5.5.8 Vee Block

Vee block, as shown in Fig. 5.21, usually in a couple are made of cast iron or steel in case-
hardening. They are generally used to hold circular workpiece for marking out or machining.5.

5.5.9 Trammel
Trammel is used for marking and drawing large circles or arcs, which are beyond the scope of
dividers (Fig. 5.22).

Fig. 5.22 Trammel

Hand Tools for Workshop

5.6 Cutting tools

Cutting tools are the tools that are used for material removal by means of shear deformation.
These involve various types of files, scrapers, chisels, drills, reamers, taps, snip or shear and
hacksaws.

5.6.1 Hacksaw
The Hack Saw is used for cutting metal by hand. It consists of a frame, which holds a thin blade,
firmly in position. Hacksaw blade is specified by the number of teeth for centimeter. Hacksaw
blades have a number of teeth ranging from 5 to 15 per centimeter (cm). Blades having lesser
number of teeth per cm are used for cutting soft materials like aluminum, brass and bronze.
Blades having larger number of teeth per centimeter are used for cutting hard materials like steel
and cast Iron.
Hacksaw blades are classified as (i) All hard and (ii) flexible type. The all hard blades are made
of H.S.S, hardened and tempered throughout to retain their cutting edges longer. These are used
to cut hard metals. These blades are hard and brittle and can break easily by twisting and forcing
them into the work while sawing. Flexible blades are made of H.S.S or low alloy steel but only
the teeth are hardened and the rest of the blade is soft and flexible. These are suitable for use by
un‐skilled or semi‐skilled persons.

Fig 5.23 Hacksaw with fixed and adjustable frame

5.6.2 Twist drill

Twist drills are used for making holes. These are made of High speed steel. Both straight and
taper shank twist drills are used. The parallel shank twist drill can be held in an ordinary self –
centering drill check. The tapper shank twist drill fits into a corresponding tapered bore provided
in the drilling machine spindle.
 Fig 5.24 Twist drills
5.6.3 Chisel
Chisels are used for removing surplus metal or for cutting thin sheets. These tools are made from
0.9% to 1.0% carbon steel of octagonal or hexagonal section. Chisels are annealed, hardened and
tempered to produce a tough shank and hard cutting edge. Annealing relieves the internal
stresses in a metal. The cutting angle of the chisel for general purpose is about 60°.
Commonly used forms of chisels are flat, cross cut, half round and diamond point chisels. Flat
chisel is used for chipping a large surface and cutting off bolts and rivets. Cross cut chisel is used
for cutting slots and key ways. Half round chisel is used to cut oil grooves in bearing. Diamond
chisel is used for cutting or forming vee grooves and also chipping plates.

Fig 5.25 Flat chisel

4.6.4 Taps and tap wrenches

A tap is a hardened and steel tool, used for cutting internal thread in a drill hole (Fig 5.26). Hand
taps are usually supplied in sets of three in each diameter and thread size. Each set consists of a
tapper tap, intermediate tap and plug or bottoming tap. Taps are made of high carbon steel or
high speed steel.

Fig 5.26 Tap and tap wrench

5.6.5 Dies and die holder

Dies are the cutting tools used for making external thread. Dies are made either solid or split
type. They are fixed in a die stock for holding and adjusting the die gap. They are made of Steel
or High Carbon Steel.
 Fig 5.27 Dies and die holder

5.8 Finishing tools

5.8.1 Scrapers
These are specially designed to remove only very small amount of metal in order to bring the
surface of a component to a high degree of flatness or roundness. i.e. it is used for removing high
spots on metal surfaces. There are three types of scraper namely: Flat scraper, half round scraper
and triangular scraper.
(a) Flat scraper is used for removing or scrapping errors in flatness of surfaces.
(b) Half round scraper is used for scrapping internal cylindrical surfaces and bearing
(c) Triangular scraper is used for removing burrs or sharp edges from internal surfaces of
brush

5.8.2 Files
A file is hardened steel, having small parallel rows of cutting edges or teeth on its surfaces.
Filing is one of the methods of removing small amounts of material from the surface of a metal
part. 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 parallel in width and tapering slightly in thickness,
towards the tip. 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 a safe edge.

Fig 5.30 Parts of a hand file

5.9.3 Screw Driver

A screw driver is designed to turn screws. The blade is made of steel and is available in different
lengths and diameters. The grinding of the tip to the correct shape is very important. A star screw
driver is specially designed to fit the head of star screws. The end of the blade is fluted instead of
flattened. The screw driver is specified by the length of the metal part from handle to the tip ( Fig.
5.35).

Fig 5.35 Screw Drivers - (a) Flat (b) Star

5.9.4 Spanner
A spanner or wrench is a tool for turning nuts and bolts. It is usually made of forged steel. There
are many kinds of spanners. They are named according to their application. The size of the
spanner denotes the size of the bolt on which it can work.