FITTING SHOP “I Foouenibx INTRODUCTI Ax OF bonch work has its own importance and carinot be dispensed with. A fiiter's work is unavoid- ably when different parts are to be assembled in position after they have been finished. An adequate knowl- Seve OF this trade is, therefore, a must. A filler skould have good working'knowledge of ali tie tools and instruments vsed in this shop. The tools used in this shop are generally made Of metals, So a fitter should be familiar with all the Hs wsed jut te mmanufneture of various tools and instruments, Although detailed metallurgical aspects of these metals are beyond the scope of this book, yet every effort has been made to aequaint the students with the maxmum details, as far as possible) 12. UASSIFICATION OF METALS All the metals used in various engineering works cnn be classified into D(H) Ferrons met. GD Non-ferrous metats. ms WO categories— Ferrous metals are those metals which contain iron as their essential constituent whereas non-ferrous acetals do not contain iron, The most common examples of ferrous metals nfe steel, cast iron etc, The non Strous petals used for engineering works pre— brags, bronze, aluminiuin, loud, ti, zine ete, / ” +4. NON-FERROUS METALS Nou-ferrons metals form a very Jarge group and inclide the precious imetals but the commonly used are 2pper, lead, tin, zine, aluminium ete, which are desctibed in the following, articles, 2.8-TOOLS USED IN FITTING-SHOP Various tools used in fitting shop are mainly classified, according to the purpose, as follow— @ Holding tools. Gv) Striking tools Gi. Marking and measuring tools (9) Dailling and boring tools (ii) Cauting tools (i) Threading tools or taps and dies, © _ All these tools are explained in detail in the following articles) (iv) Phpe fitters : Is used for bolding round bars and pipes, It grips a pipe at four points oni wface, A pipe fitter’s viee is shown in fig, 1:5 Pole penerels Handlea ‘Reombination square ix show in fg, 2.8, I conssis. ot grooved orga sr Hoan, ae HA eel a serew nt anyeequited position atone the blade, The Bice or seal |e reused It Wr yes,ane oe ee TOT Vig. 2.8. Combination Square its pats or centimeter and mitinteters. 118 avaiable tn varying lengths from 20 cm. (0 Oem. It is used for texting and selting out tight angles. 2.41. CENTRE SQUARE Aacentre square is used to find the centre of circular objects It consists of straight edge serewe fo the two ars as shown in fig. 2.9. Contre Square Fig. 29. For locating the centre of a circular object, the 80 anns of the centre square are placed! such that the two touch uke circumference of the object. Draw a line along with Wie straight edge. Similarly draw another Fine by placing the arms at another position. ‘The to Hines will intersect at point, which will be the centre ‘of the object 1.12. BEVEL PROTECTOR Devel protector is used for marking and setting out angles. It consists ofa dial divided in degrees round she enter circle from (° to 360°. The dial cai be rotated on a central stud and the Tine o£ angle is marked by the steaight edge, The straight edge can be slid longitudinally in ts seating, The Devel protector may hav a vemier attached to the dial from which readings ef angles to fractions of a degree can be obtained. A bevet protector is shown in fig. 2.10. .Aeonsigts of reo sinnighteages Tpit Sot AL FEBDT AMAIS, "The two cciges aro called blade anu stock ybinde 48 made of steel and As rivetted tO the shock which is Maeke oF east 10H oe east steel a 7 pu ep Vw Vig. 2.9. Try Square ‘In checking edges, Koop the blade perpemificular to the edge being tested. You ean easily judge whether se edges wire at right angles of not. Hor checking straightness of an edge, keep the blade over the er! fad observe. If Hght is seen between the blade and the cdge face, it is not smooth and straight aarkding out, press the stock fitmly against the work with the left hand and mark whth the seribeyy 20. STEEL RULES ‘Steel rules nre made in different sizes to sult the diverse requirements of the fitter, Ordinary we use a 12 ‘b Stoel rule (as shown in fig. 2.20) for marking and measuring, Rules aro marked in denominations of Or 1/10 of an inch and also In ceatimetres and millimetres, A steel rule should not be allowed to become ty and must bo protected from rough usage and weer, 1 4 al 129 $5 678 Vig. 2.20. Steel Foot Role 21, VERNIER CALLIPERS ‘These Instruments are widely used fer precision measurements of thickness, length, depth, diameters A vemiicr calliper consists of a beain carrying the main scale, inside and outside measuring jaws. a depth gauge bar nnd an adjustable vernier head which can be moved along the beam, ‘These are provided with an auxiliary head connected to the main head by a screw for fine adjustment, Both the heads ace provided with locking serews fo look them. Fimly at any desired position. The main head earnes the vemiier divisions or vemier scale. A vensier ealliper is shown in fig, 2.21. 5 §Y 12 19-14 48 48 17 1a 49 30 gn wD aD NI o , s / A, Veunior ColliverekaW. IYER TA grrr isee 4 {{here are a number of dilling machines used for making holes, but as far as the scape of this book ts concerned, wo shall discuss only three types of drilling machines— (0) Bench erg Mnwtehina 1 Fig, 2.95:shows @ simple type of bench drilling machine. It's proven with a Short column nnd a base for mounting on a bench, It is provided with an electric motor to delve it. Ie is sultable for drilling holes upto.20 mm dia, Itean run with a speed of 000 spm. It 1s used in tool rooms or shops where the work Is expected to be small in si#e, im} Fig. 2.5, Beoeh Driling Machine __ (i) Hand drilling machine : This type of drilling machine is operated ‘manually, It is suitable for Grilling holes upto § mm dia. It {s similar to the hand drilling machine which has. ‘been explained in the chapter of carpentary, (li) Parlable drilling machine : Is snall compact diling machine used for small drilling works. Tt | aay be brought to the work site for drilling purposes. It isequipped with a small electric motor and a switch. | Altis ee for drilling holes upto 15 mm diameter, / 231Awist DRILLS ‘Twist drills aré made from round tool steel. At the cutting end, there is a cone-shaped point. Spiral grooves are made along the sides of the body of the twist drill, which are called flutes. ‘Twist drills are available in different forms to suit the various types Of drilling work, but the most commonly used types are—parallel shank and tapered shank drills, Parallel shank is provided on small sized drills and tapered shank is provid br ils. Fi maa s provided on biggtrsized drills. Fig. 2.36 given below shows the two types ‘Shank Flute . + Fig. 2.36, Twist Dela / = / ( Osc caetometer 1S Hi instrument for making nore preciee mn: WE es OM seed come appeal Gere casurements than can be got with rutes and ly used typo of a micrometer i shown in fig. 2.22. Ieconstata of a stiff, flat, bow fine. A hardened gauging face i8 provided at one end of this bow. Exactly opposite to thie © there 18 n mnchined hbo ot Waly witty an Heide thea fito thie fite A theoddedd spittle Faced ana "anetl at Ue end to form an adjustable face, To the other end of the spindle, a thimble or sleeve is Acted which 1s Inrge enough to aide aver the outside of the hub, Ry ming the thimble, the end of the indle moves forward or backward within the jaws of the frame, Arnal ‘ Screwed pity 48 ee Thienbto fe Net reich Sleeve ~~ Frame Pig. 2.22. Micrometer On the hud, an index line is engraved, parallel to its axis, This: line is subdivided into spaces equal to the teh of the thread, When the anvils or faces touch cach other, : : the zero on the hub coincides with the zero on thimble. One complete revolution of the thimble moves the anvil for.a distance equal to the pitch of the read. . . Jn case of an ‘inchanterometer’, th plteh ofthe tread 1s 0025."The periphery ofthe bevelled edge of Umble is divided into 25 equal paris, and is masked on every Sth division thet when the thimble Is ‘ed through one small division on the bevelled edge, the spindle moves through 125th small division on Sleeve therefore, the coiresponding displacéiient of the spindle, nds cl va eciniiga: e's Tag 0-001 neh - GAUGES ‘ Have Isa plece of material of standard dimensions used for checking lengths ot angles in a work. here are a number of gauges but the commonly used gauges are explained ns follow : 1, Fitter or Fecler gauge : It is used for inspection of various parts of machines. It consists of metal 7¢s of different thickness fastened together ina holder. Bach blade has a definite thickness ranging from. + ‘34 inch to 0.025 inch, ‘To find the Lap between the two pieces, the leaves of the fecler gauge are inserted he gap one after, and tied und that blade which is neither too, loose nor too tight is obtained by ing It in the gap, The gap thickness is rend on the blade, 2. Radius gauge : 11 is employed to check extemal or intemal diameter. a Vi 2.24, Filter of Peeler Gaygs6 Depth prmge TUS used for measuring depens of Bind Hotes, slots, grooves ete, Ik consists of a novyndie hohd swith a hase which moves along the beam (ns shown Vn fig, 2.25). Fig. 2.25. Depth Gauge Fig. 2.26. Centre Gauge a cue gauge? A centre gauge's used for checking angles of thread eutting tools and for wa them on the lathe. A’eentse gauge is shown in fig. 2.26. . 5, Vernier helgit gauge + Itis used for measuring the height of parts ‘and in precision marking work. te consists of a heavy base, a vertical bar mounted to the base and carrying the main scale, a sliding head vith vemier, an auxiliary head with fine adjustment screw. A vemnier height gauge is shown in fig. 2.27,he aspen On euurting tap ie Oe Agno th sv the tapered part atatlow threads For the text jrols tnd C991 ieee reste MBO Oe the way along dhe cutting portion, Next, the s#conel tap is vised, Teo Gtlow threads newe te end at (oll threats Beginning about one-third of the way along the cutting joon, Finny, The pag oF faritehing tap se weet Te has ANHE Mheeade over the whole oF ies length ‘The tnp should he inserted porpendticnibarly to the face of the work fi whte th nirendy drilted quited stsis of Hote i Vip, 2.38 piven below ehows the three tape used for cutting internal threads, 2.36, STOCKS ANG DIES . . Stocks and dies are ured for cutting extemal screw threads on round bars, Dies are made of tool stcel and have internal threads and flutes which provide cutting edges. The threads are tapered slightly to help the to short cutting easily, Dieying- work should be started carefully because any diserepency in the starting work cannot be re- moved aerwards. The die is held in ths stock and is screwed tightly over the work. Keep the work well oiled and tum the stock clockwise with frequent backward tums until the die has covered the required distance, Withdraw the tool by tuming the stock in the reverse direction, Repeat the operation with a die which is set lo give a deeper cut.Fig. 240, shows a spring die with ifs special type of stock. 2.37, SCREW THREADS ‘As tiated already, screw threads are used as temporary fasteners, on devices for making adjustments e tnd for tramamission ef power from one part to another. Tt these different purposes, a number of Uireads forms are used, The following are two main forms of screws threads— 1, Vefornn thread, 2, Square form thread. . . Other forms are elther modified form of V-threads ox a combination of the above two forms. € 2.38, COMPARISON OF V AND SQUARE FORI OF THREADS 7 “Table glves the comparison between V-anid Square threads : Square Threads Vedireads aro stronger than square ‘Square threads are less stronget thar Vahceads threads. . ‘Vethreads’offer greater resistance to motlon than square threads and there~ fore used for fastening purposes as in ‘ease of bolts, nuts, set screws, machine screws cle, . ‘Ve-threads are cut easily and lence by dies cheaper. Square threads offer less frictional resistance to motion and therefore used for transniission of power as in case of lathes, screws, bench viccs, valve spindles, ete. ‘Square threads cannot cutby dies and hence costly2) SOME IMPORTANT SCREW THREADS. Crew Mhronds as pet ayltnbas are discussed below. Uy British standord whitworth threads BSW form of thread was Introduced by Sir fosept Whitworth and was adopted ns British suindard thrend. Irie the modified form of V-thread having angle $5: yn 0-187 of depth is soured Off At the ctost and roots, Onder proportions of this threads are shown int fig, 24 Uses 1 TSW. thrend are nsed on bolis, nus, studs ond screw facrenings for general purposes, Mae 9s ya Fle 241 BSW, Thea . (2) British standard fine (DSF) threads : This form of thread Is similar to B.S.WV. thread, but has fine pitch in relation to diameter. These threads have large effective and core diameter than B.S.W. thread and nilow fine axial adjustment, B.S.W, threads are stronger than B.S.W. threads fot a given nominal size. ‘Uses ¢ These threads are used where the connected parts are subjected to excessive vibrations as inaero pinesmotors, automobile, machine tool works etc. (3) British standard plpe (B.S.P,) threads : These threads 2ré of B.S.W. form, but have fine pitch (in ‘ation to disineter) to obviate cutting deep into the pipe. The diameter of B.S-P. thread ig specified by bore meter and not by outside diameter. - ' . Uses These threads are mainly wsed for gas, water and steam pipes. Note : The cketches of B.S.F. and DSP. threads ate similar to B.S.W. threads. (4) Meteic threads (M) t In 1893. the International Congress for.the standardisation of screw threads pied the international metric thread system. The form of thread is similar to the American standard Sept the depth of threads fs greater, (a) Flat Root Fig. 2.42, Metric Threads ‘The angle of motrie thread is 60%. The roots of the threads may be either rounded of flat, A rounded root file is recommended for both nut and bolt threads but the shape is left to the manufacturer, Figs. 2.42 (a) and (b) shown a metric thread with root flat and rounded roats respectively.)o ye torew threwds ete designated by the letter "M’ followed by the diameter and the pitch, the Wo sepataied by the sign cross ‘X', where there is.no indication of pitehy Mt shall O,mnean thas 3 Tmplied. > sabe ~ ere eee LS Fond we i ESHROMUON OL MELE UTERO: arse or example: M10 x 1:25 f. dt meant metric threads of 10 mm diameter and 1-25 mint fine plich. aeet Metrle thrends are ured for general purpose fastenings such as on bolts and nuts. These are not br power transmission 3) Square thronds : As the name implies, these threads are quite square in section (see fig. 2.43), The of these thrends are normel to the axis end hence pardilel with each other. The piteh of the thread is sr than B.S.W. thread of the same diameter. Wear and teat of these threads is less as they: are subjected 8 friction, Square thrends ate stronger then Vethreads but are more expensive to cut on the lathe. ‘Fig, 243, Square Threads, The depth of the square thread is equal to half the pitch. Uses : Square threads are uted for power transmission on feed mechani of me: spindles, bench vices, screw jacks etc. as it offers less frictional reistance to motion. (© Acme threads 1 It is the modified form ot square ahead, These threads ate eusly Yo Sot and are aaron Aime auare threads, The Ureaded angle of acme thvead i297 and depth of the thread is05P+ Das The width at the crest is equal to 03707 P as shown in fig. 2.44, }—r—4 or ° / 4 ¢ & ¢ tools, valve Fig. 2.44, Acme Threads Uses: Aeme thrends are particularly used where the nut (which i made in two parts) it required 19 engage or disengage from a screv at frequent Intervals €4. (nthe lead screw shaft of the lathe. These are Stoo frequently used on brass valves and cock works. ‘ @~ JOB:- MAKING. INTERNAL-AND EXTERNAL FHREAD ON & JOB BY : TAPPING AND DIEING OPERATION (MANUALLY). DCE sizegomm TAP SIZE 1X15 Wya ; MAKING INTERNAL ANDEXTERNAL TORTAD.ONA. DIEING OPERATION (MANUALLY). JOB-BY-PAPPINGAND LOOLS: Bench vice, hand hacksaw, flatfile, steel rule, try square, drilling machine with drill 8.5 m.m , Tap set 10*1.5 mam, , die set 101.5 mamete, AATERIAL: Mild steel flat $0*50*8 m.m_ Mild steel rod S0*10 m.m. ‘ROCEDURE:- . \.-Cut the material 50*S0*8 im.m and rod 50*10 m.m with han hacksaw. 2. After cutting filing both side and checking height edge with try square. After filing make a hole four each comer on the flat piece size 8.5 m.m with drilling- machine. ‘After drilling hold the flat piece into bench vice and’hold the taper tap in the tap handle: Bhow internal thread cut with taper tap size 10*1.5‘m.m and tum by tum use intermidate,plug tap, Complete the tapping operation. Now filing of rod finishing and champring both ends. - After filing hold the rod in the bench vice vertical posit ) Now hold the die into the die stock size.10*1.5 mm. | Now cut the thread clockwise and anticlockwise and complete the die operation. “ RECAUTION - Clean the surface plate before marking operation. Use the tap set and die stock clockwise and anticlockwise. Always use good lubricant oil a checking with try square.. 12 L f ; ++ PREPARATION.OLAJOR BY. TILING ONNON-FEBROUS METAL TO AN ACCURACY £ 0.1 m.m. P| I St oe naeaee enemies : H8MM," 2s ‘1 JOB PREPARATION. OA JOB-BY-FILING.ON, NON-BERROUS METAL UP. « TO AN ACCURACY £0.1 mm. TOOLS:- Bench vice, hand hacksaw, steel rule, single cut flat’file, try square, surface plate, ODD leg calliper, centre , Punch, marking hammer, scriber, vernier caliper. MATERIAL: — - Aluminium flat 50*50*18 m.m PROCEDURE: 1, Hold the aluminium flat into the bench vice, 2.‘Cut the material of aluminium flat with hand hacksaw. 3. After cutting filing in the on side with single cut flat file and checking straightness by try square. ; 4. Now filing second side and checking straight edge with try square, 5. Now filing on the flat side and check straightness on surface plate. 6. Marking with ODD leg caliper size 48°48 m.m. 7. After markinig punch the marked line with centre purich and marking hammer. 8. Now remove the unwanted material with the help of sirigle cut flat file and check flatness by using try. square. 9. Complete the all accurately check with the help of vernier caliper. PRECAUTION:- 1, Do not use file without handle: 2. Move the file horizontally. 3. Clean the file teeth before filing.16 3 5 JOU: - DRILLING PRECTICE.QN SORT, METALS.(ALUMUNIUM), OOLS:- Bench vice, hand hacksaw, steel rule, single cut flat file, centre punch, marking hammer, rilling machine, Drill, try square. 1ATERIAL:- Aluminum flat 50*50*8 mm. JLOCEDURE:- - Hold the aluminum flat into the bench vice. Cut the material with hand hacksaw. After cutting filing both side check straight edge with try square, + Now mark the drill centre both comer with centre punch and marking hammer, after marking, drilling, operation in the marked points. With drilling machine and drill Now finishing the both flat side with single cut flat, file. Complete the job drilling practice 'n soft metal. *RECAUTION:- Do not change the speer of drilling machine. :. Give proper feed to drilling. .. Do notuse blunt drill? + } The work piece or job should be held tightly in the drilling vice.\7 Yy JOW-G1, “Pipe threading, Fitting of Elbow, Tee, Unlon, Socket, Stopcock, Tapes, TOOLS: Pipe Vice, Pipe Die Pipe Wrench, Mandhaksaw MATERIAL::-G-1.Pipe, Elbow, Union, Socket, Stopcock, Tapes, Cotton Thread, Etc, PROCEDURE::- 1. First of all hold the job in Pipe Vice, 3 2. Set the Pipe Die and start cut the Threads, complete all four piece Threading. 3. Now fit the Stopcock and Joint with two plece of Pipes 4+ Nowwe have take a Tee and joint with Elbow pipe for increase the line. 5. Agalo increase the line we'have join a Pipe in Elbow with the help of Union. 6. Atlast fit the Tap at and of the Pipe. 2. Use lubrication while threading. 2. Movement of die should UNION Tp