HERITAGE INSTITUTE OF TECHNOLOGY

DEPARTMENT OF MECHNICAL ENGINEERING

WORKSHOP / MANUFACTURING PRACTICES (MECH1051)
WORK INSTRUCTION SHEET

FITTING SHOP
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, where as fitting deals which the
assembly of mating parts, through removal of metal, to obtain the required fit by filling, chipping, sawing, scraping,
tapping etc after the machine operations and this may or may not be carried out at the bench.
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.

TOOLS USED:
Specification
Types of Tools Name of Tools
Size Material of Construction
Jaw Width – 4’’ / 100mm Carbon Steel Jaw, Plated Steel Screw and
Fitting Vice
Jaw Opening – 4 ¾ ‘’ / 120mm Bar
A. Holding
Tools C-Clamp C-Clamp Opening capacity and load capacity
Max & Min diameter can be
V-Block Stainless Steel / Carbon
hold, Inclination
12” (Maximum measureable
Steel Rule Stainless Steel
length), Least Count
Maximum measureable length
Steel Tape Stainless Steel
Least Count
Blade : Hardened steel
Try Square Length of the blade: 6’’
B. Measuring Stock : Cast Iron or steel
Tool Case hardened mild steel or hardened and
Outside Caliper Length of the leg : 12’’ / 6’’
tempered low carbon steel
Case hardened mild steel or hardened and
Inside Caliper Length of the leg : 6’’
tempered low carbon steel
Range : 0-150mm
Vernier Caliper Stainless Steel, Carbide tipped Jaws
Least count:0.01mm
Length of the leg up to hinge Case hardened mild steel or hardened and
Odd Leg Caliper
point : 6’’ tempered low carbon steel
Scriber or Marking Length ranges from 150mm to Hardened and tempered High Carbon
C. Marking Knife 250mm Steel
Tool
Compass and Case hardened mild steel or hardened and
Length of the leg
Divider tempered low carbon steel
Centre Punch and Length : 3’’ / 4’’ High carbon steel
 Prick Punch Diameter :
Include angle : 60° / 90°
Length of the blade H.S.S or low alloy steel
Hack Saw
Teeth per unit length (cm): 5-15 Hardened Teeth
D. Cutting Tool
0.9% to 1.0% Carbon steel (annealed,
Cold Chisel Blade width and length
hardened and tempered)
Diameter of the hole
E. Drilling Tool Twist Drill High speed steel
No of Starts , Shank type
Weight : 200gm
Ball Peen Hammer Head Length Forged high carbon steel
Face Dimension
Weight
Cross-Peen
F. Striking Tool Head Length Forged high carbon steel
Hammer
Face Dimension
Weight
Straight Peen
Head Length Forged high carbon steel
Hammer
Face Dimension
Length : 12’’
G. Finishing Cross Section : Round / Flat / Heat-treated high carbon steel
Files
Tool Triangular PVC / Wooden handle
No of cuts : Double Cut
Taps M-8 x 1.25,
HSS
H. Threading Tap Wrenches Standard Size
Tool Dies and Die- M-8 x 1.25,
HSS
Holders Standard Size
Size / Length :
Screw Driver Type : Magnetic / Nonmagnetic
Screw Head Type : Slotted /
Type : Box/Ring/Socket/
Spanner Chromium-Vanadium alloy Tool Steel
Adjustable
I. Miscellaneous

Spirit Level Length x Width Aluminum/Molded Plastic/Plastic

 Figure 1.1: Bench Vice (Fittings)

Figure 1.2: V-Block Figure 1.3: C-Clamp

Figure 2.1: Try Square Figure 2.2: Steel Rule and Steel Tape
 Figure 2.3: Calipers

Figure 2.4: Vernier Caliper

Figure 3.1: Odd-Leg Caliper

Figure 3.2: Scriber Figure 3.3: Divider Figure 3.4: Compass

/Prick Punch

Figure 3.5: Punches

Figure 4: Hacksaw frame with blade

Figure 6.1: Ball Peen Hammer Figure 6.2:Cross Peen Hammer Figure 6.3: Ball Peen
Hammer
 Figure 7

Figure 8.1: Taps and Tap Wrench Figure 8.2: Dies and Die Holder
Figure 9.1: Screw Driver

Figure 9.2: Spanners

 JOB NO. MECH1051/03/A
Name of the Job: Making a Gauge from MS Plate
Raw materials:Mild Steel Plate
Raw material size:60mm Length x 50mm Width x 5mm Thick
Drawing of the job:

All Dimensions are in mm

SEQUENCE OF OPERATION FOR MALE GAUGES: MECH1051

Sl. No. Operation Schematic diagram Tools required

Scale, Try-square, scriber,

Filling, Marking and Parting
1. Hack Saw, Prick Punch,
off Required Length.
Ball Peen Hammer

Marking and Filling three

2. edges for parallelism and Flat file, Try-square
squareness.

Surface preparation for

3. Chalk, Water
Marking.
 Marking Construction Line as Scale, Protractor, Scriber,
4.
required. Centre Punch, Hammer

Sawing along marking lines up

5. Hack saw
to required length as vertically.

Sawing along marking lines for

6. other side up to required length Hack saw
as vertically.

Sawing the 30° inclined surface 30

7. Hack saw
up to required length. 0

Sawing the other side 30°

8. inclined surface up to required Hack saw
length.
30
0
 Filling all saw-cut edges for
9. Flat file
final finishing.

10. Checking Standard component

SEQUENCE OF OPERATION FEMALE GAUGES: MECH1051

Sl. No. Operation Schematic diagram Tools required

Marking Construction lines as Scale, Protractor, Scriber,

1.
required Centre Punch, Hammer.
 Sawing the 30° inclined surface
2. Hack saw
up to required length.

Same operation as Sl. No. 2 for

3. Hack saw
the other side of V shape.

Filling all saw-cut edges for

4. Flat file
final finishing.

5. Checking Standard component

 JOB NO: MECH1051/04
Name of the Job: Making internal Threads on Male or Female Gauge plate and
External thread on MS Rod to fit the internal thread.
Raw Materials: Mild Steel Plate and MS Rod
Raw material size: 60mm Length x 50mm Width x 5mm Thick and MS Rod of 100mm long x 8mm dia.
Drawing of the Job:

M8
20

50

20
`

15

20

15

60
SEQUENCE OF OPERATION FOR INTERNAL THREAD ON MALE GAUGE AND EXTERNAL
THREAD ON MS ROD TO FIT THE INTERNAL THREAD: MECH1051
Sl. No. Operation Schematic diagram Tools required
Surface preparation for
1. Chalk, Water
Marking.

Location points A and B Scale, Scriber, Centre

2. marking suitable Punch, Odd-leg Caliper,
construction lines. Hammer

Make 2 Nos. of drill holes Scale, Divider, Centre

3.
with ø6.8 at And B. Punch, Hammer

Tapping the drill hole A

Twist Drill, Drilling
and B for making the
4. Machine, Taps and Tap
internal thread of diameter
wrench
8mm.
 Filing, Marking and
5. Parting off required length Hack saw
of MS Rod.
100

Try-square, scriber, Hack

6. Filing edges of the rod.
saw

Marking the external

7. thread at two ends of the Rough File, Try-Square.
rod with 20mm each. 20 20

Die operation for making

8. external thread at both end. Die and Die-stock.
20 60 20

Checking for thread.

9. By thread gauge.
20 20 20

SEQUESNCE OF OPERATIONS ARE SAME AS IN MALE GAUGE FOR MAKING THE INTERNAL THREAD ON
FEMALE GAUGE AND FOR EXTERNAL THREAD ON MS ROD ALSO ARE SAME AS MENTION ABOVE.
 JOB NO. MECH1051/03/B
Name of the Job: Making a Gauge from MS Plate
Raw materials: Mild Steel Plate
Raw material size: 60mm Length x 50mm Width x 5mm Thick
Drawing of the job:
 JOB NO. MECH1051/03/C
Name of the Job: Making a Gauge from MS Plate
Raw materials: Mild Steel Plate
Raw material size: 60mm Length x 50mm Width x 5mm Thick
Drawing of the job:
 JOB NO. MECH1051/03/D
Name of the Job: Making a Gauge from MS Plate
Raw materials: Mild Steel Plate
Raw material size: 60mm Length x 50mm Width x 5mm Thick
Drawing of the job:
 JOB NO. MECH1051/03/E
Name of the Job: Making a Gauge from MS Plate
Raw materials: Mild Steel Plate
Raw material size: 60mm Length x 50mm Width x 5mm Thick
Drawing of the job: