NFC Institute of Engineering & Fertilizer

Research Faisalabad

Department of Electrical Engineering

First Semester:-
Course Title:
WORKSHOP
Topic:
FITTING SHOP
Submitted To:
Engr. Bushra Riaz
Submitted By:
Hafeez Ali
Roll. No:
18-ELE-43

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 FITING WORKSHOP
INTRODUCTION:-
Machine tools are capable of producing work at a faster rate, but, there are occasions when
components are processed at the bench. Sometimes, it becomes necessary to replace or repair
component which must be fit accurately with another component on reassembly. 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. The term
‘bench work’ refers to the production of components by hand on the bench, whereas fitting deals which
the assembly of mating parts, through removal of metal, to obtain the required fit. Both the bench work
and fitting requires the use of number of simple hand tools and considerable manual efforts. The
operations in the above works consist of filing, chipping, scraping, sawing drilling, and tapping.

IMPORTANCE:
In engineering, particularly in heavy and medium engineering, even to-day, with the use of
automatic machines, bench work and fitting have important roles to play to complete and finish a job
to the desired accuracy.

APPLICATIONS:
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.

FITTING SHOP TOOLS:

These are the helping hands while fitting and assembling a machine or a part of it. They can be
hand driven or power driven. Some main fitting tools are listed below:
· Measuring Tools
· Marking Tools
· Holding and Supporting Tools
· Cutting Tools
· Striking Tools
· Drilling Tools
· Threading Tools
· Loosing and Tightening Tools
· Filling Tools
· Boring Tools
· Reaming Tools
· Tacking Tools
· Dieing Tools
· Counter Boring
· Counter Sinking
· Chamfering Operation Tools
· Building Tools
· Punching Tools

Here we will discuss some of the following tools in fitting workshop:

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 STRIKING TOOLS
These tools are used for striking or hammering or imprinting something on the work piece. They have
heavy head attached to the handle.

Hammer:
A hammer is a tool consisting of a weighted "head" fixed to a long handle that is swung to deliver
an impact to a small area of an object. This can be, for example, to drive nails into wood, to shape
metal (as with a forge), or to crush rock. Hammers are used for a wide range of driving, shaping, and
breaking applications.

Types of Hammers:-
Ball‐ Peen Hammer:
Ball‐ Peen Hammers are named, depending upon their shape and material and specified by their
weight. A ball peen hammer has a flat face which is used for general work and a ball end, particularly
used for riveting.

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Cross‐Peen Hammer:
It is similar to ball peen hammer, except the shape of the peen. This is used for chipping, riveting,
bending and stretching metals and hammering inside the curves and shoulders.

Straight‐Peen Hammer:
This is similar to cross peen hammer, but its peen is in‐line with the hammer handle. It is used
for swaging, riveting in restricted places and stretching metals.

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Mallet Hammer:
A mallet is a kind of hammer, often made of rubber or sometimes wood, that is smaller than a
maul or beetle, and usually has a relatively large head. The term is descriptive of the overall size and
proportions of the tool, and not the materials it may be made of, though most mallets have striking
faces that are softer than steel.
Rubber Hammer:

Wooden Hammer:

Claw Hammer:
A claw hammer is a tool primarily used for driving nails into, or pulling nails from, some other
object. Generally, a claw hammer is associated with woodworking but is not limited to use with wood
products. It is not suitable for heavy hammering on metal surfaces (such as in machining work), as the
steel of its head is somewhat brittle.

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 LOOSENING AND TIGHTENING TOOLS
Spanner:
A wrench or spanner is a tool used to provide grip and mechanical advantage in applying torque
to turn objects usually rotary fasteners, such as nuts and bolts or keep them from turning.

Types of Spanners:-
Open End Spanner:
Open-ended spanners are versatile, single-piece tools that can be used on most types of
fasteners around the home and across the industries. They are the characteristic spanner type!

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 Their head has two jaws forming a U-shaped profile with two parallel flat sides.

The opening between the jaws is the width of the fastener head so the tool can be slipped around
the fastener from the side. This width indicates the size of the tool in metric and AF ('across flats')
imperial measurements.

Ring Spanner:
A ring spanner is a simple, double-headed, single-piece spanner with a profile set in a looped
head.

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 The loop is placed over the head of the fastener and the spanner profile pushes against the flat
sides of the fastener head to turn it. Ring spanners are less likely to slip off the fastener than open-
ended spanners because they make contact with the fastener on all sides. This means they can be
turned in wider arcs more easily, making the task quicker.

The most common ring spanner profile is the 12-point (or 'bi-hex') profile, so-called because it
has 12 points and troughs.

Combination Spanner:
A double-ended tool with one end being like an open-end wrench or open-ended spanner, and
the other end being like a box-end wrench or ring spanner. Both ends generally fit the same size of
bolt.

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Adjustable Spanner:
The most common type of adjustable wrench in use today. The adjustable end wrench differs
from the monkey wrench in that the gripping faces of the jaws are displaced to a (typically) 15 degree
angle relative to the tool's handle, a design feature that facilitates the wrench's use in close quarters.
The modern adjustable end wrench.

Pipe Wrench:
A tool that is similar in design and appearance to a monkey wrench, but with self-tightening
properties and hardened, serrated jaws that securely grip soft iron pipe and pipe fittings.

L-key:
A L key, Allen key or Allen wrench is a tool used to drive bolts and screws with sockets in their heads.

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Screw Driver:
A screwdriver is a tool, manual or powered, for screwing and unscrewing (inserting and
removing) screws. A typical simple screwdriver has a handle and a shaft, ending in a tip the user puts
into the screw head before turning the handle.

Types of Screw Drivers:-

Double Edge:
The slot screw driver has a single slot in the fastener head and is driven by a "common blade"
or flat-bladed screwdriver. It was the first type of screw drive to be developed, and for centuries it was
the simplest and cheapest to make. Uniquely among common drives, it is straightforward to
manufacture a slot head or drive by hand. The slotted screw is commonly found in existing products
and installations, and is still used in some simple carpentry, and applications where little torque is
needed.

Four Edge:
A cross or double-slot screw driver has two slots, oriented perpendicular to each other, in the
fastener head; a slotted screwdriver is still used to drive just one of the slots. This type is usually found
in cheaply-made roofing bolts and the like, where a thread of 5 mm (0.20 in) or above has a large
flattened pan head. The advantage is that they provide some measure of redundancy: should one slot
be deformed in service, the second may still be used and the tool cannot slip out.

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 MEASURING TOOLS
Steel Rule:
The steel rule is a basic measuring tool. When used correctly, a good steel rule is a surprisingly
accurate measuring device. Some people confuse rules and scales. A scale is a measuring device
used by architects and engineers that assists them in making drawings to a scale other than full size.

Vernier Caliper:
A vernier scale is a visual aid to take an accurate measurement reading between two
graduation markings on a linear scale by using mechanical interpolation; thereby increasing
resolution and reducing measurement uncertainty by using Vernier acuity to reduce human
estimation error.
The vernier is a subsidiary scale replacing a single measured-value pointer, and has for
instance ten divisions equal in distance to nine divisions on the main scale.

Types of Vernier Calipers:-

Inside Caliper:
It is also known as internal caliper. It is used to measure the internal diameter. Its edges are
turned outwards so that they hold work piece. It is used to measure the diameter of a hole or width of
a slot.

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Outside Caliper:
It is also known as external caliper. Its jaws are turned inside to hold the work piece from outside.
It is used to measure the external diameter and also the thickness.

Screw Gauge:
Screw gauge is a device incorporating a calibrated screw widely used for accurate
measurement of components in mechanical engineering and machining as well as most mechanical
trades, along with other metrological instruments such as dial, vernier, and digital calipers. Screw
gauges are usually, but not always, in the form of calipers (opposing ends joined by a frame). The
spindle is a very accurately machined screw and the object to be measured is placed between the
spindle and the anvil. The spindle is moved by turning the ratchet knob or thimble until the object to be
measured is lightly touched by both the spindle and the anvil.

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Steel Tape:
A tape measure or measuring tape is a flexible ruler and used to measure distance.
It consists of a ribbon of cloth, plastic, fiber glass, or metal strip with linear-measurement
markings. It is a common measuring tool. Its design allows for a measure of great length to be easily
carried in pocket or toolkit and permits one to measure around curves or corners.

Try Scale:
Try square is used for making and testing angles of 90degree. It consists of a steel blade , riveted
into a hard wood stock which has a protective brass plate on the working surface. Another type is the
all-metal square, with steel blade and cast iron stock. Sizes vary from 150 to 300mm,according to the
length of the blade.

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 MARKING TOOLS
Scriber:
A scriber is a hand tool used in metalworking to mark lines on work pieces, prior to machining.
The process of using a scriber is called scribing and is just part of the process of marking out. It is
used instead of pencils or ink lines, because the marks are hard to see, easily erased, and inaccurate
due to their wide mark; scribe lines are thin and semi-permanent. On non-coated work pieces marking
blue is commonly used to increase the contrast of the mark lines.

Divider:
Divider, instrument for measuring, transferring, or marking off distances, consisting of two
straight adjustable legs hinged together and ending in sharp points. It is used principally in drafting for
the accurate transfer of dimensions from a measuring scale and in machine shops for scribing lines on
surfaces, usually machined, with dimensions taken from a ruler. A compass is essentially a divider in
which one of the points has been replaced by a pencil or other marking device. The compass is useful
for scribing circles or arcs of circles; it usually includes a scale to indicate the radius of the circle being
scribed.

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Punching Operation:-
Center Punch:
This is similar to the dot punch, except that it is ground to a conical point having 90 degrees
included angle. It is used to mark the location of the holes to be drilled.

Alphabetic Punch:
It is used to mark the alphabetic letters on the surface.

Number Punch:
Also known as letter stamps or number stamps, letter punches are used to emboss the
impression of a letter or number into a work piece. They are most common in the reverse image, this
allows the end result to be immediately readable, and however they may be made as a positive image.
This is essential in the case of die or mold making and ensures that the finished product will be
readable, as a die is a negative image.

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 CUTTING TOOLS
Metal Chisel:
A chisel is a tool with a characteristically shaped cutting edge (such that wood chisels have
lent part of their name to a particular grind) of blade on its end, for carving or cutting a hard material
such as wood, stone, or metal by hand, struck with a mallet, or mechanical power.

Hack Saw:
A hacksaw is a fine-toothed saw, originally and mainly made for cutting metal. The equivalent
saw for cutting wood is usually called bow saw. Most hacksaws are hand saws with a C-shaped frame
that holds a blade under tension.

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File:
A file is a tool used to remove fine amounts of material from a work piece. It is common in
woodworking, metalworking, and other similar trade and hobby tasks. Most are hand tools, made of a
case hardened steel bar of rectangular, square, triangular, or round cross-section, with one or more
surfaces cut with sharp, generally parallel teeth. A narrow, pointed tang is common at one end, to
which a handle may be fitted.

Types of File:-
Rectangular File:
Designed with material removal in mind, square files excel at enlarging square holes and
rectangular slots.

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Square File:
Gradually tapered and cut on all four sides. Used for a wide variety of tasks.

Round File:
Round in cross-section and gradually tapered over their length. They are used for enlarging
round holes or cutting scalloped edges.

Half Round File:

Has one flat and one convex surface, and either tapering slightly or maintaining an even
thickness, width, or both over their length.

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Triangular File:
Triangular in cross-section, which may taper gradually, often to a point on smaller files. The
sides may be equal in cross-section, or have two long and one short surface.

Cut File:
A file is a hand cutting tool made of high-carbon steel, having a series of teeth cut on its body by
parallel chisel cuts.

Types of Cut File:-

Single Cut File:
Are used when smooth finish is desired.

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Double Cut File:
Are used for fast removal of metal and easy clearing of chips.

Teeth File:
Classification according to coarseness or spacing of the teeth is confined to single- and double-
cut files. There are six main classes: rough, coarse, bastard, second-cut, smooth, and dead smooth.
The number of teeth per inch varies considerably for different shapes and sizes.

Types of Teeth File:-

Big Teeth File:
Is used for rough cut.
Small Teeth File:
Is used for smother cut.

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Drill bit:
It used for making round holes. Drill bit can be used with different blades. It is made up of steel.
It rotates at a very high speed. Drill bits are cutting tools used to create cylindrical holes, almost always
of circular cross-section. Drill bits come in many sizes and have many uses. Specialized bits are also
available for non-cylindrical-shaped holes.
The shank is the part of the drill bit grasped by the chuck of a drill. The cutting edges of the drill
bit are at one end, and the shank is at the other end.

Drill chuck key:

A chuck key is a device used on a keyed chuck to match the gears on the chuck. Chuck keys
are quite small, and can easily be misplaced. Thus, most manufacturers of hand power drills with
keyed chucks add a key holder for the chuck key on the power cord. It is also used to loosen the
bolts.

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Counter sinking tool:
Tool for making a hole with the top part enlarged so that the head of a screw or bolt will lie
flush with or below the surface. A cross-hole countersink is a cone-shaped tool with a cutting edge
provided by a hole that goes through the side of the cone.
Reamers:
Tools which are used in reaming are called as reamers. They are used to control the diameter
of hole. They are used to improve the finishing of whole surface, they are made of high carbon steel.
They can be hand reamers or machine reamers.

Tap:
They are used for internal threading by inserting them into the hole at right angel to the face of
hole. In hand tapping, three taps are used. They are inserted into hole and moved clockwise and then
anti-clockwise direction to fix the impression. They are made of high carbon steel.

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Tap Handle:
Hand taps are used by inserting them in handle. It is a type of tap wrench where force is applied by
palm. It requires more pressure and force.

Die:
It is used for external threading on nuts and bolts. They are also made of high carbon steel. They
are available in different pitches and can be used according to desired threads.

Die-handle:
Die handle is used for making external threads by human effort. Die is inserted into die-stock
and then rotated by hand.

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 Fitting Shop Operations
Sawing operation:
Metal sawing is done by hack saw. A hacksaw is a fine-tooth saw with a blade under tension in
a frame, used for cutting materials such as metal or bone. Hand-held hacksaws consist of a metal arch
with a handle, usually a pistol grip, with pins for attaching a narrow disposable blade. A screw or other
mechanism is used to put the thin blade under tension. The blade can be mounted with the teeth facing
toward or away from the handle, resulting in cutting action on either the push or pull stroke. On the
push stroke, the arch will flex slightly, decreasing the tension on the blade.

Filing operation:
Filling is done by a file. A file is a metalworking and woodworking tool used to cut fine amounts
of material from a work piece. It most commonly refers to the hand tool style, which takes the form of
a hardened steel bar with a series of sharp, parallel ridges, called teeth. Most files have a narrow,
pointed tang at one end to which a handle can be fitted.

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Punching operation:
Punching in metalworking is the process of using a punch press to push a punch through the
material and into a die to create a hole in the work piece. A scrap slug from the hole is deposited into
the die in the process. Depending on the material being punched this slug may be recycled and
reused or discarded. The whole walls will show burnished area, rollover, and die break and must
often be further processed. Punching is often the cheapest method for creating holes in sheet metal
in medium to high production.

Reaming Operation:
Operation Used to accurately size and finish hole previously formed by drilling is called
reaming operation. This is done with the help of a reamer.

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Drilling operation:
Drilling is a cutting process that uses a drill bit to cut or enlarge a hole in solid materials. The
drill bit is a multipoint, end cutting tool. It cuts by applying pressure and rotation to the work piece,
which forms chips at the cutting edge.

Counter sinking operation:

Counter sinking is the operation of making a cone shaped enlargement of the end of a hole to
provide a recess for a flat head screw or countersink rivet fitted into the hole. The tool used for
countersinking is called a countersink. Standard counter sinks have 60°, 82° or 90°included angle
and the cutting edges of the tool are formed at the conical surface. The cutting speed in counter
sinking is 25 % less than that of drilling.

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Counter boring Operation:
Counter boring is the operation of enlarging the end of a hole cylindrically. The enlarged hole
forms a square shoulder with the original hole. This is necessary in some cases to accommodate the
heads of bolt, studs and pins. The tool used for counter boring is called a counter bore. The counter
bores are made with straight or tapered shank to fit in the drill spindle.
The cutting edges may have straight or spiral teeth. The tool is guided by a pilot which extends
beyond the end of the cutting edges. The pilot fits into the small diameter hole having running clearance
and maintains the alignment of the tool. These pilots may be interchanged for enlarging different sizes
of holes. Counter boring can give accuracy of about 9 0.05 mm. The cutting speed for counter boring
is 25 % less than that of drilling operation.

Spot facing Operation:

Spot facing is a machining operation where material is removed from a surface to make it flat
and smooth, usually for a fastener or bearing. It is usually required on work pieces that are forged or
cast. A counter bore is typically used to cut the spot face, although end mills are also used. Only
enough material is removed to make the surface flat.

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Taping operation:
Taps and dies are cutting tools used to create screw threads, which is called threading. A tap
is used to cut the female portion of the mating pair (e.g., a nut). A die is used to cut the male portion
of the mating pair (e.g., a screw). The process of cutting threads using a tap is called tapping,
whereas the process using a die is called threading.

Dieing operation:
A die is a specialized tool used in manufacturing industries to cut or shape material using a
press. Like molds, dies are generally customized to the item they are used to create. Products made
with dies range from simple paper clips to complex pieces used in advanced technology.
Forming dies are typically made by tool and die makers and put into production after mounting
into a press. The die is a metal block that is used for forming materials like sheet metal and plastic. For
the vacuum forming of plastic sheet only a single form is used, typically to form transparent plastic
containers (called blister packs) for merchandise. Vacuum forming is considered a simple molding
thermoforming process but uses the same principles as die forming. For the forming of sheet metal,
such as automobile body parts, two parts may be used, one, called the punch, performs the stretching,
bending, and/or blanking operation, while another part, called the die block, securely clamps the work
piece and provides similar, stretching, bending, and/or blanking operation. The work piece may pass
through several stages using different tools or operations to obtain the final form. In the case of an
automotive component there will usually be a shearing operation after the main forming is done and
then additional crimping or rolling operations to ensure that all sharp edges are hidden and to add
rigidity to the panel.

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Filleting Operation:
Blending and filleting operations are important tools in any contemporary geometric modeling
environment. The ability to smooth corners or to continuously connect two adjacent surfaces into a
single object is considered mandatory in any modeling environment.

Chamfering Operation:
Chamfering removes the burrs and sharp edges, and thus makes the handling safe.
Chamfering can be done by a form tool having angle equal to chamfer which is generally kept at 45°.

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