i FITTING SHOP ™ Specimen Instruction Sheet : stool Name of the Job 6th Nov Date of Commencement + Term end Date of Completion Time Taken Material required SN. Operation Ms Square pipe Gauges & Tool required 1) The size of the supplied material should be checked with the drawing by means measuring Instruments. Steel foot Rule. Clamp the piece ‘A’ in the Bench vice & Flat file, Vice clamp, file the three adjacent surfaces. ‘ Try square. Unclamp the piece ‘A® apply chalk to the » plain surface. ¢ Chalk (white) Steel foot ru Place the piece ‘A’-on the surface plate & aliper, Scriber, Try Sq. do the marking, by means of marking tools. ; lot Mark the lines with the ep punch. “Pep punch, Hammer. Clamp piece ‘A’ in bench vice and remove the surplus material in length and width. Hand Hacksaw. AF Unelanp-the piece ‘A’ from the vice and’ Drilling mach’ we the surplus from the Dri v cétttre by drilling transfer piece ‘A’ to fitting benclf vice. File piece ‘A’ correctly up to the marking Files, file brush, lines check for squareness and dimensions. _Try square.FITTING SHOP Introduction : Manufacturing processes are broadly classified into four categories: 1) Casting processes. 2) Forming processes. 3) Fabrication processes. 4) Material removal processes. Inall these processes components are produced with the help of either machines or ~ manual effort. The attention of a fitter is required at various stages of manufacture starting from marking to assembling and testing the finished goods. Working on components with hand tools and instruments mostly on work benches is generally referred to as “Fitting work’. ‘The hand operations in fitting shop include marking, filing, sawing, scraping, drilling, tapping, grinding etc. using hand tools or power operated portable tools, Measuring and inspection of components and maintenance of equipment is also considered as important work of fitting shop technicians. ‘A) Work Holding Tools: 1) Bench Vice:- The bench vice is a device commonly used for holding the work pieces. When the vice handle is tuned in a clockwise the moving jaw forces the work against the fixed jaw. The greater the pressure applied to the handle the tighter is the work held. The body of the vice is made of cast-iron. Hardened. steel plates with servations to ensure better gripping of the work are fixed on the faces of the two jaws. Jaw caps made of soft material such as aluminium or galvanized iron(G.L.) sheet are used to protect finished surfaces of the gripped in the vice. Vices are specified by the maximum width that can be held or the maximum opening between the jaws. Varying from 75mm to 300mm. Y- Block with clamp: The V-block is a rectangular or square block with a v- groove on one or both sides, opposite to each other. The angle of the V is usually 900. V-block with a clamp is used to hold cylindrical work securely, during marking of measurements or for measuring operation. Material C.1. or hardened steel. Size: 50 to 150mm. 2 B) Marking And Measuring Tools: 1) Surface Plate;- The surface plate is used for testing the flatness of the work piece and other inspection purposes. It is also used for marking on small works, It is more precise in flatness than the marking table.Surface plates are made of C.I. or hardened steel, ground and scraped to the required precision. Now-a-days surface plates made of special granite stone are manufactured in wide range of precision grades, colors and sizes, It is specified by length x width x height x grade. Example: 600 x 400 x 100 x grade A has a flatness up to 0.00Smm. 2) Universal Seribing Block:- This is used for scribing lines for layout work and checking parallel surfaces. 3) ‘Try-square:- Try-square is used for checking the squareness of small works, when extreme accuracy is not required. The size of the try-square is specified by the length of the blade. Ex. 10cm, 30cm ete. 4) Combination set:- A combination set consists of a rule, square head, centre head and a protractor. This may be used as a rule, a square, @ depth gauge, for marking mitres ( oblique ) (45 degrees), for measuring and marking angles. The rule in made of tempered steel with grooves. 5) Seriber:- A scriber is a slender steel rod, used to soribe or mark lines on” metal work pieces. so called “Jenny caliper” or ‘Hermaphrodite’. This is used for marking parallel lines from a finished edge and also for locating the centre of round bars..They are specified by the height of the Jeg up to the hinge point. Example: 100mm, 150mm ete. 6) Odd-leg caliper:- This is al: Divider:- This is used for marking circles. Arcs laying out perpendicular Zi lines, bisecting lines, etc. Size ranges from 100mm to 300mm. 8) Dot Punch:- This is used to locate centre of holes and to provide a small centre mark for divide point etc. For this purpose, the punch is ground toa conical point having 60° included angle. _ This 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 centre where holes are to be drilled. ‘The centre punch mark facilitates easy location of the drill tip and centre accurately. 9) Centre Pune 10) Calipers:- These are used with the help of steel rule to check outside and inside measurements. They are specified by the maximum length measured. Sizes vary from 100mm to 300mm. 11) Vernier Calipers:- These are used for measuring outside as well as inside dimensions accurately. It may also be used as a depth gauge. In the figureshown, 19 main scale divisions are divided into 20 equal parts in the Vernier scale. Hence, least count of the vernier = Imain scale division — 1 vernier scale division = 1 — 19/20 = 0.05mm. ‘The size is specified by the maximum measurement jt can make ranging from 150 to 300mm, The accuracy of the instrument depends on the least count, varying from 0.1 to 0.02. Other types of verniers include dial vernier, digital vernier with more accuracy etc. 12) Vernier height Gauge:- The vernier height gauge, clamped witha cerper itis used for layout work. An offset seriber is used when it is required to take measurements from the surface, on which the gauge is Standing, The accuracy and working principle of the gauge are the same as sane ofthe vernier caliper. The capacity of the height gauge is specified by the maximum height it ean measure. It varies from 150mm to 1000mm. 13) Outside Micrometer:~ This is used for measuring external dimensions accurately. A micrometer of 0 to 25mm range with an accuracy of 0.01mm. These are available in different ranges with interchangeable anvils varying from 0.25mm to 2000mm in sizes and 0.01 to 0.001 in accuracy. They include thread micrometers to measure wall thickness of tubes, etc. 14) Inside Micrometer:- This is used to measure inside dimensions accurately, Fig, shows an inside micrometer of range 25 to 150mm with extension rods, These are available in different ranges and accuracies. ©) Cutting Tools: 1) Hacksay 2) - The hacksaw is used for cutting metal by hand. It consists of a frame which holds a thin blade, firmly in position. The blade has a number of cutting teeth. The number of teeth per 25mm of the blade length or teeth per inch(TPI) is selected on the basis of the work material and thickness being cut shows two types of hacksaw frames with a blade fixed, The teeth of the hacksaw blade are staggered, as shown which is known as a ‘set of teeth’. This make the slots wider than the blade thickness, preventing the blade from jamming, Chisels:- 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 a hard cutting edge. Annealing relieves the internal stresses in the metal, The cutting angle of the chisel for general purpose is 60 degrees.inati ing Plier:- This is made of tool steel and is used for Combination cutting Plier: This is mat ; 2 Siting as well as for gripping the work. The handles of the pliers used by electricians are insulated with PVC covering to protect from electric shocks. 4) 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 with machines. The following are the types, sizes and designations of twist drills; 1) Straight shank Millimetres from 0.4mm onwards Inches from 1/64” onwards Letter drills A to Z f Number drills 60 to 20 a 2) Taper shank Millimetres 3 to 100 Inches 1/8" to 4” 5) Taps and tap Wrenches:- A tap is a hardened steel tool, used for cutting jnternal threads after drilling a hole. Hand taps are usually supplied in sets of three for each diameter and thread pitch. Each set consists of a taper tap, intermediate tap and plug or bottom tap. The following are the stages involved in tapping operation. 1) Select the correct size tap, with the desired pitch. A thread is specified by its shape, size and pitch. 2) Select the correct size tap drill, usually indicated on the tap. 3) Drill the hole. 4) Secure the tap in the tap wrench. 5) Insert the first or taper tap in the drilled hole and start turning clockwise by applying downward pressure. 6) Check the alignment of the tap with the hole axis(verticality) with a try-square and correct it if necessary, by applying sidewise pressure while turning the tap. 7) Apply lubricant while tapping. 8) Tum the tap forward about half a turn and then back until chips break Joose. Repeat the process until threading is completed with intermediate and bottom taps. 9) Remove them carefully, If it gets stuck, work it back and forth gently to loosen, Note : 1) It is good practice to drill a small countersunk, about the depth of one thread to ensure that a base is not thrown up while tapping the hole. -2) While tapping in a blind hole, remove the tap and clear the chips often so that the tap can reach the bottom of the hole. 6) Dies and Die-holders:- Dies are cutting tool used for making external threads. Dies are made either solid or split type. They are fixed in a die holder for holding and adjusting the die gap. They are made of tool steel or high carbon steel. The following are the stages in producing external threads: 1) Prepare the work with chamfer at its end. 2) Select the correct size die. 3) Position the die in the die holder. Tighten the set screw so that the die is held firmly in its place. In case of adjustable die, set the die to cut oversize threads first. 4) Fasten the work firmly in a vice. * 5) Place the die over the chamfered end of the work start cutting threads by tuming it clockwise while applying downward pressure. Apply cutting fluid while threading in steel. 6) Tum back the die for the chips to break loose. Continue until threading is completed. 7) Check the threaded work to see if it fits the tapped hole or nut. If the fit is too tight, adjust the die for a slight deeper cut and complete the threading again. Note:- A tap is not adjustable, so it is better to tap first and then cut the ‘external threads to fit the tapped hole. D) Finishing Tools: 1) Files: Filing is one of the methods of removing small amount of material 2) from the surface of a metal part. A file is a hardened steel tool, having slant parallel rows of cutting edges or teeth on surfaces. 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 end. It is provided with double cut teeth on the faces, single cut on one edge and on teeth on the other edge, which is known as safe edge. Types of Files:- Files are classified according to their shape, cutting teeth and pitch or grade of the teeth, the various types of files in use based on their shape. Figure shown the files in use. ifTypeofFile 9 -——- Description and Use a) Hand file:- Rectangular in section and tapered in thickness but parallel in width. The faces carry double cut teeth and one of the edges single cut. The other edge, known as safe edge, does not have any teeth and hence this file in also known as safe edge file. It is useful in filing a surface which is at right to an already finished surface as in Fig. b Flat file:- It is rectangular in section and tapered for 1/3 length in width and thickness towards the point. The faces carry double cut teeth and the edges carry single cut teeth. It is a general purpose file. c) Square file:- It is square in section and carry double cut teeth on all the four faces. It is tapered for 1/3 of its length towards the point. Square files are used for filing corners and slots. It is also used to keyways and slots. @) Triangular file:- It is of equilateral triangular in section and tapers towards the tip. The faces are double cut and the edges sharp. These files are used to file angular hole, and recesses. Used for sharpening wood saws. ©) Round file:- It is tapered for 1/3 length with double cut on large coarse grades. Used of filing out round, elliptical and curved openings. ‘ f) Half round file:- The half round file has one flat and one curved side. The flat side is double cut and the curved side is single cut. It is not semicircle but only about 1/3 of circle. Second cut and smooth grades are used. This is an extremely useful double purpose file for flat surfaces and for curved surfaces which are too large for the round file to be used. Swiss or Needle files:- 150mm long with double cut teeth. Used for’ filing corners, grooves, narrow slots, etc. Cut refers to ‘ Single cut’ and ‘Double cut’ files, Single cut files have rows of teeth running in one direction, across their faces and double cut files have a second row of teeth cut diagonally to the first raw as shown. Single cut files are used with light pressure to produce smooth finish. These are widely used for finishing on turning jobs. Classification of files based on the grade or the pitch of the teeth, is shown in Fig. 7 g\piscetlaneo™s Tools i i id material and __ Hammers are named depending on their'shape and mate 1) Hammers oir weight, A ball peen hammer has a flat face which is used ified by # soe 3 spel wrk and the ball end particularly used for riveting. They weigh for 8 from 202m to 1.5kg. Spanners:- 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 as shown is Fig. They are named according to the shape and application. The size of the spanner denotes to size of a bolt on which it can work. 2) Screw drivers:- 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 of the blade to correct shape is very important. Screw driver is specified by the length of the steel rod. Screw drivers with small diameter rods are known as corinectors. For better grip on screws which are small and at not easily accessible depths, Philips ( star ) screw drivers are used > F) Safe and Correct Practices: ; The following are some of the safe and correct work practices in bench work. Fitting shop: 1) Position the work piece area such that the cut to be made is close to the vice. This practice prevents springing. Saw breakage and personal injury. 2) Use soft jaws when holding finished work surfaces in a bench vice. 3) Position the work in a vice so that it does not overhang into an aisle of other area where a person might accidentally brush against it. 4) Select the hacksaw blade pitch and set, most suitable for the material and | the nature of the cutting operation. © 9) Apply force only on the forward (cutting) stroke, relieve the force on the f Tetum stroke. 9) Start a new blade in another place when a blade bendsds during a cut. This Prevents bending and blade breakages, ‘uta small groove with a file in sharp corners, where a saw cut is to be Started. The groove permits accurate positioning of the saw and also ) Roe stripping of the teeth, e. eee thin metal strips, clamp them between two pieces of wood.» Gagne through both the wood and the metal prevents the saw teeth from 8 in and bending the metal.HeeL TANG a Tale [ae LEN@TH-——. alee PARTS OF FILE DOUBLE CuT FILE i aTAW--PEATES—— ——— FLX e> JAW ee Ter be JAW . “GOLLAR | BENCH Vice SURFACE PLATE _INNER MEASURING] NtBS LOCKING SCREW FINE. ADTUSTIN® UNIT e- BEAM ov MALN SCALE [ [ETE = 5 / DEPTH GAUGE VERNIER = STIN STARE FINE AdjusTEN& SCREW MOVABLE JAW Ww VERNIBR CALIPER is CENTRE Punch fait OT PUN CER? Ou ENNY, TSI ae, INSIDE CALIPER. DIVIDER gee, 4SPINDLE = SCRIGER, SCRIBER HOLDER ROCKER jars MENT ARM ecREW ~ SPLNDLE NUT UNIVERSAL SURFACE GUAGE BEAM stock ---~-[ TRY SQUARE COMBENATION SBTSIZE OF SQUARE LENGTH OF SQURE LENGTH OF SHANK SHANK DAM [4—|— axt's FLuTé piTcH DIAM - = ica aE oF THREAD a MAJOR DLAt * HELIX ANGLE MENOR DLA- REAR FLANK FRONT FLANK CHAMFER. LENGTHHACKSAW FRAME FLAVA ELA wing NOY wa OVERALL LENGTH ie NomiNAL LENGTH TeeTH PIN HOLE HACKS AW BLADE BALL PEIN ‘ F aye Hol HANDLE STRIKING FACE BALL PEIN HAMMER:BoDY CLEARANCE CHISEL ged EDGE . CoRNER, WEB THICKNESS FACE PART OF TWIST DAILL