FITTING SHOP

INTRODUCTION:
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.

DEFINITION:
Fitting is a manufacturing process which refers to assembling of parts together
and removing metals to secure necessary fit.

FITTING SHOP TOOLS

1. Striking Tools:

 Hammer
A tool with a heavy metal head mounted at right angles at the end of a handle,
used for jobs such as breaking things and driving in nails.
 Types of Hammer:

 Cross peen Hammer

A cross peen hammer is a hammer used by blacksmiths to complete metal
work. The wedge-shaped end of the hammer allows you to make the metal fuller when
used with heat. The main functions of a cross peen hammer is forging and riveting.

 Ball peen Hammer

A ball peen hammer is a hammer with two ends on the head, one that is round
and the other flat. Sometimes called a machinist's hammer, a ball peen is a good choice
for working with metal. Its steel head is harder than that of a claw hammer, so is less
likely to chip on impact. Ball peen hammers are commonly used to drive cold chisels,
set rivets, and bend and shape metal.
 Claw Hammer
A claw hammer is a tool primarily used for pounding nails into, or extracting
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.

  Sledge Hammer
 A sledgehammer is a tool with a large, flat, often metal head, attached to
a lever (or handle). The size of its head allows a sledgehammer to apply
more force than other hammers of similar size. Along with the mallet, it shares the ability
to distribute force over a wide area. This is in contrast to other types of hammers, which
concentrate force in a relatively small area.
 Wooden Mallets
Wooden mallets are usually used in carpentry to knock wooden
pieces together, or to drive dowels or chisels. A wooden mallet will not deform the
striking end of a metal tool, as most metal hammers would. It also is used to reduce the
force driving the cutting edge of a chisel, giving better control. Hardwood mallets are
also used to knock in cricket bats.

1. 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.
 Centre Punch
A center punch is used to mark the center of a point. It is usually used to mark
the center of a hole when drilling holes. A drill has the tendency to "wander" if it does
not start in a recess. A center punch forms a large enough dimple to "guide" the tip of
the drill. The tip of a center punch has an angle between 60 and 90 degrees.

 Prick Punch
A prick punch is similar to a center punch but used for marking out. It has a
sharper angled tip to produce a narrower and deeper indentation. The indentation can
then be enlarged with a center punch for drilling. The tip of a prick punch is 40 degrees
(the angle depends on what type of prick punch one is using).
 Alphabet Punch
Alphabet 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.

 Divider
Divider is tool used for transferring measurement and laying out circles and arcs.
Divider is similar to a compass but often have two metal points rather the pencil and one
point.
 Surface Plate
A surface plate is a solid, flat plate used as the main horizontal reference plane for
precision inspection, marking out (layout), and tooling setup. The surface plate is often
used as the baseline for all measurements to a work piece.

2. Measuring Tools:

 Vernier Caliper
A vernier caliper is a measuring device used to precisely measure linear
dimensions. It is a very useful tool to use when measuring the diameter of a round
objects like cylinders because the measuring jaws can be secured on either side of the
circumference. The least count of vernier caliper (0.01).
 Micrometer screw Gauge
The screw gauge is an instrument used for measuring accurately the diameter of a
thin wire or the thickness of a sheet of metal.  It consists of a U-shaped frame fitted with
a screwed spindle which is attached to a thimble. Parallel to the axis of the thimble, a
scale graduated in mm is engraved. This is called pitch scale. A sleeve is attached to
the head of the screw. The least count of micrometer screw gauge (0.001).

 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, fibre glass, or metal strip with linear-measurement
markings Surveyors use tape measures in lengths of over 100 m (300+ ft).
 Internal Caliper
 A caliper whose legs turn outward so that it can accurately measure inside dimensions,
as the inside diameter of a pipe. Examples from the Web for inside caliper. The tool can
be used as an outside caliper, as an inside caliper, and as a divider. 

 External Caliper
 A caliper whose legs turn inward so that it can measure outside dimensions, as the
diameter of a rod. Origin of outside caliper.  Outside calipers are used for measuring
outside dimensions such as the outside diameter of a tube or a piece of bar stock.
 Try Square
A try square is a woodworking or a metalworking tool used for marking and measuring a
piece of wood. The square refers to the tool's primary use of measuring the accuracy of
a right angle (90 degrees); to try a surface is to check its straightness or
correspondence to an adjoining surface.

 Screw pitch Gauge

A thread gauge, also known as a screw pitch gauge or pitch gauge, is used to measure
the pitch or lead of a screw thread. The uppermost gauge in the image is an ISO
metric pitch gauge, the larger gauge in the center is for measuring the
Acme thread form, and the lower gauge is for Whitworth screws.
 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.

3. Cutting Tools

 Chisel
A long-bladed hand tool with a beveled cutting edge and a handle which is struck with a
hammer or mallet, used to cut or shape wood, stone, or metal.
 Hacksaw
A hacksaw is a fine-toothed saw, originally and mainly made for cutting metal. Most
hacksaws are hand saws with a C-shaped frame that holds a blade under tension. Such
hacksaws have a handle, usually a pistol grip, with pins for attaching a narrow
disposable blade. The frames may also be adjustable to accommodate blades of
different sizes. A screw or other mechanism is used to put the thin blade under tension.

 Drill Bit
Drill bits are cutting tools used to remove material to create holes, almost always of
circular cross-section. Drill bits come in many sizes and shapes and can create different
kinds of holes in many different materials. In order to create holes drill bits are usually
attached to a drill.
 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 Files:
 Square File
Square files are machinist's files that can be used in slots and key ways. They are also
used for roughing (removing material quickly) when turning round drill holes into square
slots.
 Round File
Round files are machinist's files and, just like half round files, they can be used for
creating semicircular grooves, finishing and deburring concave surfaces. They are often
used in jewellery making to create detailed patterns in bracelets.

 Half round File

Half round, ring and marking files are exceptionally versatile machinist's files The flat
sides of a half round file can be used in the same way as a flat or hand file.
 Triangular File
A triangular file is a specialized tool for trimming and sharpening edges. Its unique,
three-sided design makes it a great tool for sharpening hard-to-reach places such as
saw teeth.

 Flat file

Flat files are flat on the top and bottom, but they taper in both thickness and width along
the length of the metal portion of the tool. In other words, the file is thicker and wider
near the handle while it is thinner and has less width near the tip.
 Single cut File
Single-cut files have rows of teeth cut parallel to each other at an angle of about 65
degrees from the centerline. Single-cut files are used for sharpening tools, finish filing
and draw-filing. They are also the best tools for smoothing the edges of sheet metal.

 Double cut File

A file with a surface cut into two series of parallel ridges crossing each other usually at
less than a right angle, both ridges being diagonal to the center line of the file.
 Tap
A tap cuts or forms a thread on the inside surface of a hole, creating a female surface
which functions like a nut. The three taps in the image illustrate the basic types
commonly used by most machinists.

 Die
A die cuts an external thread on cylindrical material, such as a rod, which creates a
male threaded piece which functions like a bolt. Dies are generally made in two styles:
solid and adjustable. The dies shown to the right are adjustable.
 Reamer
Reamer is a form of rotary cutting tool which is used in metalworking and in drilling to
enlarge the size of existing holes. It provides a finish of high quality and straightness
upon the completion of an operation.

FITTING SHOP OPERATION

1. Measuring operation:
Measuring is a process in which we consider the physical features of an object. We get
knowledge about its length, mass, height, internal or external diameters, depths etc.
This is done with the help of measuring tools like Vernier calliper, callipers, screw
gauge, ruler.
2. Marking operation:
Marking out or layout is the process of transferring a design or pattern to a work piece,
as the first step in the manufacturing process. Marking out consists of transferring the
dimensions from the plan to the work piece in preparation for the next step, machining
or manufacture. After measuring form measuring tool, some marking tools are used e.g.
scriber, tri-square, dividers etc, mark the desired area on work piece.

3. Sawing operation:
A saw is a tool consisting of a hard blade, wire, or chain with a toothed edge. It is used
to cut through relatively hard material, most often wood. The cut is made by placing the
toothed edge against the material and moving it forcefully back and forth. Cutting the
work piece through this method is called sawing operation.
4. Filling Operation:
Filing is a material removal process in manufacturing. Similar, depending on use, to
both sawing and grinding in effect, it is functionally versatile, but used mostly for
finishing operations. Filing helps achieve work piece function by removing some excess
material and deburring the surface.

5. Drilling operation:
Making a hole with the help of drill bit is called drilling. Drilling is one of the most
complex machining processes. The chief characteristic that distinguishes it from other
machining operations is the combined cutting and extrusion of metal at the chisel edge
in the centre of the drill.
6. Reaming operation:
The process of enlarging the hole is called reaming. There are many different types of
reamer and they may be designed for use as a hand tool or in a machine tool, such as
a milling machine or drill press. A reamer is a type of rotary cutting tool used
in metalworking. Reaming can be done on a drilling machine by using a hand reamer or
using a machine reamer.

7. Boring Operation:
Occasionally a straight and smooth hole is needed which is too large or odd sized for
drills or reamers. A boring tool can be inserted into the drilling machine and bore any
size hole into which the tool holder will fit. Boring is the process of enlarging a hole that
has already been drilled.
8. Counter Boring Operation:
Counter boring is the process of enlarging the entrance of a hole with a counter bore, or
other similar tool to a specified diameter and depth. Counter bores provide a square
shoulder so that a cap screw or bolt head may sit flush or below a surface.

9. Counter Sinking Operation:

The cutting of a bevelled edge at the end of a hole so that the head of a screw can rest
flushes with the work piece surface. A countersink is a conical hole cut into a
manufactured object, or the cutter used to cut such a hole.
10. Spot facing Operation:
Spot facing is facing the area around a bolt hole where the bolt's head will sit, which is
often done by cutting a shallow counter bore, just deep enough "to clean up" that is,
only enough material is removed to get down past any irregularity and thus make the
surface flat.

11. Tapping Operation:

Tapping is the operation of cutting internal threads in a hole using a cutting tool called
tap. Most of the industries use the conventional method hand tapping. So there is a
scope to develop the machine for tapping operation.
12. Fillet Operation:
Fillet operation is a rounding of an interior or exterior corner of a part design. An interior
or exterior corner, Fillet geometry, when on an interior corner is a line of concave
function, whereas a fillet on an exterior corner is a line of convex function (in these
cases, fillets are typically referred to as rounds).

13. 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°.  Chamfers may be formed in either inside or outside adjoining
faces of an object or room. They are also used to "ease" otherwise sharp edges, both
for safety and to prevent damage to them.