FITTING SHOP

PRODUCT REALISATION TECHNOLOGY PRACTICUM (IC-141P)

CENTRAL WORKSHOP
INDIAN INSTIUTE OF TECHNOLOGY MANDI
IIT MANDI PRODUCT REALISATION TECHNOLOGY PRACTICUM 2020

FITTING SHOP

1. Introduction
Even in the most mechanized industry, although majority of the work can be finished with the help of
machines, there are certain operations, which have to be carried out manually using hand tools.
For example:
i) In production shops, when two or more parts are to be assembled.
ii) Sometimes it necessary to replace or repair a component, which must fit accurately with another
component on re-assembly, Fitting
Fitting is the process of assembling two or more metal parts together by removing excess material so as
to obtain a required fit.
OR
It is the process of removing unwanted material with the help of hand tools, from a given stock
(workpiece) for making a component or fitting one in the other to form a matting or fitting pair.
Ex:- 1) key and keyhole 2) A Bush and a shaft.
Fitting requires the use of various hand tools and considerable manual effort. Fitting work involves a
large number of hand operations to finish the work to desired shape, size and accuracy. The hand
operations in the Fitting shop include marking, sawing, chipping, Filing, scraping, drilling, tapping,
Dieing, Fitting etc.
2. Engineering Materials
Materials that are used in the engineering Practice are called Engineering Materials. These have
physical, mechanical and chemical properties.

Figure 1: Classification of engineering materials

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2.1. Metals
A metal is a solid (Exception: Mercury) having weight. It is opaque and a good conductor of
heat and electricity.
2.2. Non-Metals
These are available in the form of liquids, gases or solids such as wood, stone, rubber, plastic,
ceramic, concrete, asbestos, etc.
2.3. Ferrous Metals
Iron containing metals such as pig iron, cast iron, wrought iron, carbon steel, Alloy steel, Nickel
steel, etc., are called ferrous metals. These can be attracted by magnets and are susceptible to
rusting.
2.4. Non-Ferrous Metals
Non-Ferrous metals are those, which do not contain iron. Metals like Gold, Silver, Copper,
Aluminium, Tin, Platinum, and Nickel, Bronze, etc, and its alloys are Non-Ferrous metals.
These can neither rust nor can be attracted by magnets.
2.5. Cast iron
It is an Iron based material containing 91-94% iron and other elements such as Carbon (2-4%),
Silicon (0.4-2.8%), Manganese (0.25-1.25%), Sulphur (0.2%max) and Phosphorous
(0.6%max).
Types of Cast iron: - Gray cast iron, malleable iron, white cast iron.
2.6. Steel
Steel is an alloy of iron and carbon. Besides this, it also contains Silicon, Manganese, Sulfur,
and Phosphorous.
One of the differences between Cast iron and steel is the amount of carbon percentage.
Based on the carbon content, steel is divided into
• Low Carbon Steels- the carbon content ranges from 0.03-0.35%. Low carbon steels are
also called as soft or Mild steel (M.S).
• Medium Carbon Steels-the carbon content ranges from 0.35-0.6%.
• High Carbon Steels-The carbon content ranges from 0.6-1.7%
2.6.1. Mild steel (MS)
Mild steel may be defined as an alloy of iron (91-94%), and carbon (0.15-0.35%). Besides
this, it also contains Silicon, Manganese, Sulfur, and Phosphorous. Low carbon steels are
also called soft or mild steel. These steels are used for bolts and nuts, structural work,
axles, shafts, etc

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2.6.2. Alloy Steel/Tool Steel

In alloy steel in addition to carbon and iron, alloying elements such as chromium,
Nickel, Vanadium, etc. are mixed. Ex: - Stainless steel, High Speed steel (H.S.S) (Tool
steel). Tool steel is widely used in the manufacturing of cutting tools.
3. Fitting Tools
Tools used in Fitting practice may be classified into the following categories.
• Holding Tools
• Marking and Measuring Tools
• Cutting tools
• Finishing Tools
• Striking Tools
• Miscellaneous Tools
3.1. Holding Tools
Vice
A Vice is a tool used to hold the work piece (job) in position while various operations are
being carried out.
(a) Bench vice
(b) Machine vice
(c) Leg vice
(d) Pipe vice
(e) Hand vice
Bench vice
The vice used for bench work is called bench vice. The benchwork includes filing,
sawing, and threading operations. It consists of a cast iron body carrying a fixed jaw and
movable jaw. Both the jaws are made of cast steel and are brought together by means of
a hand-operated Screw. Separate cast steel plates known as ‘jaw plates’ are fixed to the
jaws by means of set screws which can be replaced when worn out. The face of the jaw
plates has teeth (serrations), which helps in gripping the work firmly.

Specification: the width of the jaws determines the size of the vice.

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Figure 2: Bench vice

Machine vice
Machine vice is used to hold workpiece in Machine tools. Machine vice is able to tilt and
swivel. It is mounted on the table of a Machine. For example, drilling machines, milling
Machine and shaping machines.

Figure 3: Machine vice

Leg vice or Black smith’s vice

It is used for holding a workpiece that has to be cut, chipped or hammered. It consists of
a fixed jaw with long leg and movable jaw that can be moved by means of a hand-
operated screw.

Figure 4: Leg vice

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Pipe vice
It is used for holding round section parts such as pipes, tubes.

Figure 5: Pipe vice

Hand vice
It is used for carrying work on small jobs, such as screws, keys, rivets, etc., which cannot
be held in the Bench vice. It consists of two jaws that can be operated by means of a wing
nut.

Figure 6: Hand vice

V-block with Clamp

V-block is a rectangular or square block with v-grooves on one or both sides, opposite to
each other. The angle V is usually 90 degrees. V-blocks are used for checking the
roundness of cylindrical workpiece and for marking centers accurately. Material:
Hardened Steel or Cast Iron.

Figure 7: V-block clamp

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3.2.Marking and Measuring Tools

Surface plate
Surface plate is a plane surface. The surface is machined to very fine limits. The plate
is constructed in such a way that it will not warp or twist. It is used for –testing the
flatness of finished workpiece. Providing a base support for ‘marking gauges’ or
‘scribing block’. Testing the accuracy of Try square.
Material: Cast iron or hardened steel or granite stone.
Specification: It is specified by length × width × height x grade.

Angle plate
It consists of two faces machined at right angles (90 degrees) to each other. A number
of slots are cut on both the horizontal and vertical faces as shown in figure 8. These
slots enable the work piece to be held firmly by means of bolts and nuts. It is also used
to support work piece, when you are using the surface gauge for marking out.
Material: Gray Cast iron

Scribing block or surface gauge

A scribing block has three parts-base, spindle and scriber. The base of the scribing block
is machined to have a flat surface. A Vertical spindle fitted on the base carries a scriber
and by adjusting the screw, the scriber can be fixed to any inclination and height along
the spindle.
It is used for scribing lines on work pieces and also used for checking parallel surfaces.
The Scribing block can be used to locate accurately the centres of round bars in
conjunction with the Vee-block.
Specification: Height of the Vertical spindle

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Figure 8: Marking and measuring tools

Scriber
A Scriber is a thin steel rod with a pointed end or ends, one of the ends may be bent at
right angles to allow access to holes. It is used to scribe (or) mark lines on the metal
workpieces. Scribers are available in several sizes and types. The point should be
ground to a 30 degrees angle and kept sharp for accuracy.
Material: High carbon steel (hardened and tempered).
Specification: It is specified by its length and diameter.

Try Square or Engineers Square

Try square also called ‘Engineering Square’ is one of the basic tools used in fitting
work. It consists of a steel blade riveted exactly at 90 degrees into a hard steel stock of
rectangular cross-section as shown in the figure. The stock acts as a fence and the blade
as guide for marking.
It is used for:
• Checking squareness or perpendicularity of workpiece.
• Testing for straightness.
• Marking straight lines (at right angles) on workpiece.
Material: Steel (hardened and tempered)

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Specification-the Size of Try-square is specified by the length of the blade (100mm,

150mm, and 200mm).

Figure 9: Scriber

Figure 10: Try Square

Steel rule or Steel scale

It is used for measuring and marking the required dimensions on the workpiece. The
scale is graduated in millimeters, centimetres and inches. Least count of normal steel
rule is 1 mm.

Figure 11: Steel Scale

Spring Divider
It is used for scribing (marking) circles, arcs, bisecting lines and perpendicular lines on
metal workpiece. It also used for transferring dimensions from scales to objects.
Material- Tool steel (Hardened &Tempered).
Specification-Max length /radius which can be scribed

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Figure 12: Outside and inside calliper

Figure 13: Spring divider

Spring calliper
Calliper is devices used for measuring and transferring the inside \outside dimensions
of components. Callipers are of two types, viz, outside spring caliper and inside spring
calliper.
Material- Tool steel

Outside spring calliper: It is used for measuring the outer diameter of shafts (rods)
and thickness of parts.
Inside spring calliper: It is used to measure the internal diameter/dimensions of parts

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Figure 14: Method to use inside callipers

Figure 15: Method to use outside callipers

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Jenny callipers
Jenny callipers are used for marking and layout work. It is used to draw parallel lines,
locating the centre of round bars. It is also known as odd leg calliper or hermaphrodite
calliper.

Figure 16: Jenny callipers

Centre Punch
It is used for marking round indentations on metal surfaces. This provides a centre for
locating the sharp end of the divider point and centre for holes that are to be drilled. It
is also used for marking points along a line, which enables to cut the workpiece easily.
The point angle should be ground to 90 degrees
Material: High carbon steel.
Specification: By length and angle.

Figure 17: Centre punch

Dot punch
It is used for marking points along a line which enables to cut of the workpiece easily.
The point angle should be ground to 60 degrees

Figure 18: Dot punch

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Letter punch
It has square body with a tapered end. At this end, a projection, corresponding to the
replica of the letter to be marked is made. It is used to punch Alphabetic letters (A to Z)
on metal workpiece.

Figure 19: Letter punch

Number punch
It is similar to letters punch in construction but has numbers at its end. The numbers
used are from 0 to 8 (six used as nine also). It is used to punch numbers on metal
workpiece.

Vernier calliper
These are used for measuring outside as well as inside dimensions accurately. It may
also be used as a depth gauge.
Example- to measure outer diameter of shafts and cylinders, to measure inner diameter
of holes and depth of holes.
The main scale is divided into millimetres. In this case 49 main scale divisions ie 49
mm is divided into 50 Vernier scale divisions.
One Vernier scale division equal to (49/50) 0.98 mm
Hence, Least count of the Vernier calliper (LC) = 1 main scale division – 1 Vernier
scale division
= 1MSD - 1 VSD
= 1mm- (49/50) mm =0.02 mm
Total reading =Main scale reading (MSR) + Least count (LC) × Vernier Coinciding
Division

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Figure 20: Vernier calliper

Vernier height Gauge

The Vernier height gauge, clamped with a scriber, is shown in Fig. 21. Vernier height
gauges are particularly suitable for marking off accurate distances and centre locations.
It is also used in inspection of work pieces. The accuracy and working principle of this
gauge are the same as those of the Vernier calliper.

Figure 21:Vernier height gauge

Micrometre
External micrometre is used to measure external diameters and lengths. The degree of
accuracy is high.
Pitch = distance moved on barrel
No. of rotations given to thimble
= 0.5 mm
1
= 0.5 mm
Least count of micrometer = pitch/ No of divisions on the thimble.
= 0.5 mm / 50 = 0.01 mm.

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Total reading =Barrel scale reading (MSR) + Least count × Thimble scale reading
(TSR)

Figure 22: Micrometre

3.3. Cutting Tools

Hack saw frame with blade.
The hacksaw is used for cutting metal by hand. The hacksaw blade has a number
of teeth ranging from 5 to 15 per centimeter. Lesser number of teeth is used for
cutting materials like Aluminium, brass and Bronze and large number of teeth is
used for cutting hard materials like steel, C.I, etc. Hack saw blades are fitted either
in a solid frame or adjustable frame to accommodate different lengths of blade.
It is made of high-speed steel. The hacksaw blades are specified by its material,
length, width, thickness and pitch of the teeth. The common dimensions are length
250-300 mm, width 13 mm-16 mm, thickness 0.6 to 0.8 mm, pitch 1 to 1.8 mm.
The blades are fixed with teeth facing forward and the teeth are staggered, which
are known as ‘set of teeth’. These make slots wider than blade thickness, preventing
the blade from jamming

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Figure 23: Hacksaw blade

Twist drill
The twist drills are used for making holes. The drills are made of HSS (high speed
steel) with a straight or taper shank. The straight shank drills are held in drill chuck
and fitted to the spindle of drilling machine and the taper shank is directly fitted to
the spindle. The drills are manufactured to standard sizes in specified steps. A bench-
drilling machine is commonly used in workshops

Figure 24: Twist drill

Flat chisel
Chisels are used for removing surplus metal from the work piece. They can be used
as a substitute when files and hacksaw blades are impossible to use.
Material - High carbon steel or tool steel having octagonal or hexagonal cross-
section. Specification- Length and width of the edge. The process of removing metal
using a chisel is called ‘chipping ‘and is shown in Fig. 25.

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Figure 25: Method of chipping using a chisel

Figure 26: Flat chisel

Taps and Tap wrenches

A tap is a hardened steel tool, used for cutting internal threads in a drilled hole. Hand
taps are usually supplied in sets of three for each diameter and thread size. Each set
consists of a (i) Taper or first tap (ii) Intermediate or second tap and (iii) plug or
bottoming or third tap. In hand tapping, the tap is rotated with the help of a tap
wrench. These taps are identical in all features except in the taper lead. For
identifying the type taps quickly the taps are either numbered as 1, 2, and 3 or rings
are marked on the shank.

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Figure 27: Tap and wrench

Figure 28: Die holder

Dies and die –holder

Dies are the cutting tools used for marking external threads. Dies are made either
solid or split type. They are fixed in a die –holder for holding an adjusting the die
gap. They are made of tool steel or high carbon steel.
3.4. Finishing Tools
Files
A file is a cutting tool used to remove small amount of material from the surface of
the workpiece and also helps in giving a smooth surface finish. A number of teeth,

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parallel and inclined at suitable angle are cut on the flat surface of the file. The
various parts of a file are shown in figure the main parts of the file include,
Tang: It is the pointed part that fits into the wooden handle.
Heel: It is end of the tang that forms a curved edge.
Face: It is the portion of the file on which cutting teeth are formed.
Point: It is the end opposite the tang
Files are often tapered along their length but they may also be parallel.
Material: tool steel (hardened)
Specification: length, single cut /double cut, shape and pitch.
Example Length (say 400 mm)
Single cut /Double cut
Shape (say square cross –section)
Pitch or grade (say smooth)

Figure 29: Parts of file

Files are classified and named according to

(a) Size/length (b) cut (c) shape and (d) pitch /grade.
(a) Size: the size of the file is identified by its length. It is the distance from the point to
the heel excluding tang. The selection of the length of the file varies depending on
the size of the job.
S.No. Size (length) Application
1 100-150 mm Used for fine work and small sized jobs
2 150-250 mm Used for medium sized work
3 250-400 mm For general and large sized work
(b) Cut: Based on the cutting teeth, files are classified as single cut files and double
cut files

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Figure 30: Single cut file and double cut file

Single cut file: In single cut file, the teeth are cut in parallel rows across the faces
of the file and normally inclined at an angle of 60 degrees with the centerline of the
face.
Double cut file: A double cut file has two sets of teeth crossing each other as shown
fig. one set of teeth are cut similar to a single cut file and the other set runs diagonally
across the first set and are normally inclined at an angle of 10 degree to the center
line of the face.
Single cut files give better finish when compared to double cut files but at the same
time removes material at a comparatively slower rate.

(c) Shape of files: Files are classified based on the shape of their cross-section.
• Flat files are used for general work or finishing flat surfaces.
• Squares files are used for filing square corners, rectangular slots, keyways,
enlarging a square or a rectangular hole etc.
• Triangular file or three-square files are used mainly for filing corners with
angles less than 90 degrees.
• Round files are used for filing concave surface and also for enlarging round holes.
• Half-round file the curved face of the half-round file is used for filing concave
surfaces and the flat face is used for filing convex surfaces.
• Knife edge file is used for filing narrow slots and corners having angles less than
90 degrees

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Figure 31: Files based on their shapes

(d) Pitch of teeth /grade

Pitch refers to the spacing between two consecutive teeth. Table shows the
classification of files based on their pitch. The files are listed in descending order
of their roughness.

Description Single cut Double cut Uses

Rough. For rapid removal
8 teeth/cm of
Large amounts of
material from softer
materials.
Bastard Rapid removal of
12 teeth/cm Small amounts of
material.
Second cut. Used for filing on
16 teeth/cm harder materials.
Gives good surface
finish
Smooth. Used for smooth
20-24 surface finish.
teeth/cm Removes small
amounts of
material.
Dead Used for accurate
Smooth. and smooth surface
>40 finish.
teeth/cm

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3.5. Striking Tools

Hammers: The hammer is defined as a device used to deliver blows to an object
or strike another object, in the sense that it is used for driving nails, fitting parts and
breaking up objects. It is also used for striking purposes while punching, bending,
chipping, and riveting. Available in various shapes and structures, hammers are
designed for specific purpose. The hammer consists of a handle to which a heavy
head, usually made of metal is attached, with one or more striking surfaces. The
hammer is specified by its weight (125 g to 1500 g) and the shape of the pein.
Different types of hammers are straight pein hammer, ball pein hammer, cross –
pein hammer
Material Cast steel or carbon steel.
Ball pein hammer: This is the most common type of hammer which has a ball-
shaped end of the head opposite to the striking face. It is used for all kinds of
engineering works. The ball end being useful for sheet metal forming and it is made
in weights from 1000gm to 1.5kg. It is used for riveting and chipping.
Cross-pein and straight pein hammer: These have blunt, chisel-shaped ends on the
head opposite to the face. It is used for bending, stretching, hammering into
shoulders, curves.

Figure 32: Types of hammer

3.6. Miscellaneous Tools

Anvil: It provides the necessary support during punching and chipping by resisting
the heavy blows given to the workpiece by hammer. The beak is used in sheet metal
work for bending the sheet metal to round shapes.
Material-The body is made of mild steel or cast steel with a hardened top face.

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Figure 33: Anvil

File card: It is a metal brush used for cleaning the files.

Figure 34: File card

4. Fitting Operations
4.1. Marking and Measuring
The marking is the first step in fitting. Marking on the work can be done by setting out
dimensions with the help of a working drawing. Generally, one end of workpiece is filed flat
and the measurements are taken from this reference end. The measuring instruments used in
fitting are scale, Callipers, Vernier caliper, micrometre, height gauge etc. Marking tools used
in fitting are Scriber, Dot punch, Scribing gauge etc.

4.2. Filing
Filling is the process of removing burrs from cuts; clean the face of cuts and to give the final
shape to a workpiece. The flatness and square ness of the surfaces finished by filing are
checked with try square.
Methods of filing: a) Cross-filing b) Draw filing
Cross-filing- this method is used for efficient removal of maximum amount of metal in the
shortest possible time. It may be noted that the file must remain horizontal throughout the
stroke (long, slow and steady) with pressure only applied on the forward motion.

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Draw filing-this method is used to remove file marks and for finishing operations. Here, the
file is Griped as close to the work as possible between two hands. In this method of filing, a
fine cut file with a flat face should be used.

Figure 35: Cross filing

Figure 36: Draw filing

Sawing: It is the method of removing excess material quickly with the help of hand hack –
saw. The surfaces are to be finish filed after sawing

Chipping: It is the process of removing unnecessary thick layers of metal using cold chisel
and hammer.

Drilling: It is the operation of producing circular holes in a metal piece with the help of
bench drilling machine and drilling tools.

Tapping: It is the process of generating internal threads in a ready hole using a set of three
hand taps.

Dieing: It is a manual operation of generating external threads on a round rod or pipe using
a die and die holder.

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Fitting /Assembly: After finishing the individual pieces as per dimensions they are joined
/fitted for an assembly.

Safe and correct practices:

• All the tools and measuring instruments are to be cleaned and kept in the respective
places when not is use.
• The sliding parts and pins are to be properly lubricated.
• The vice should not be over tightened; otherwise it may damage the spindle.
• The sharp edges of a chisel or scriber are to be covered with a cap to avoid getting
damaged and to prevent accidents.
• The handles of hammers are to be checked for cracks etc.
• The surface plate has to be covered and kept when not in use and tools and jobs
should not be thrown on the surface plate to avoid damage to the surfaces.

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Figure 37: Methods of filling

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Figure 38: Use of different types of files

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Figure 39: How to use a hacksaw

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Experiment Fitting

Aim To make fillet, chamfer, drilling and tapping on mild steel flat
Drawing

Material required Mild steel flat [size: 50×50×10 mm], 1 number

Equipment and • File
tools required • Steel rule
(Please illustrate • Try square
equipment and tools • Scriber/ Odd leg calliper
using appropriate • Hand hacksaw
drawings) • Drill bit
• Bench vice
• Dot punch and centre punch
• Rough and smooth flat file
• Flat chisel
Sequence of • Filing
operations • Checking flatness and squareness
• Marking and measuring
• Sawing
• Drilling
• Tapping
• Finishing
Procedure • Remove burrs on the piece and check dimension suing steel rules
• Clamp the piece in the bench vice and file the edges using rough and
smooth files
• The flatness, straightness and squareness i.e. right angle between
adjacent sides are checked with help of Try-square
• Chalk is applied on the surface of MS flat
• Using dot punch, dots are punched along the above scribed lines.
• Using hack saw, the unwanted portions are removed
• Using flat chisel, the unwanted item is filed

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• Corners are filed using a square or triangular file.

Precautions • Keep proper Discipline in the shop. Do not play with the tool because
they bare sharp edges.
• All file should be fitted with suitable handle at the end of the file.
• Hacksaw blades should be kept in good condition.
• Always keep file away from others cutting tool.
• Use proper file for different material.
• Use wire brush for cleaning the files.
• Apply pressure during forward stroke of hacksaw

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