STUYABLE

78

27 445 12

25

736

QTY- 02 No

444
AL ENESONS AREIN
 FITTING SHOP
Specimen Instruction Sheet

Name of the Job

Date of
Commencement :
Date of Completion
Time Taken
Material required
S.N. Operation Gauges & Tool required

1) The size of the supplied material should Steel foot Rule,

be checked with the drawing by Mcasuring Tape.
means
measuring Instruments.
2) Clamp the piece of pipe in Bench Vice Try square, Hack Saw,
& Cut the pieces as per dimensions. Angle Grinder.
3) Unclamp the piece of pipe & Check all By Steel rule & measuring
Dimension on the surface plate. Tape
4) Again clamp all the pipes one by one & By Hack Saw & Angle
remove the surplus Material in length & Grinder
in cutting cross section.

5) Grind the excess material correctly to the

Try Square, Files, Grinder
Marking lines to check squareness &
Angular cross section.
6) Unclamp the piece of pipe & drilled the
Pipe as per dimension Drilling Machine, H.S.
Drill, Machine vice.
 FITTING SHOP

Introduction :
categories:
processes are broadly classified into four processes. 4) Material
Manufacturing 3)Fabrication
Casting processes. 2) Forming processes.
1)
removal processes.
either machines or
produced with the help of
components are stages of manufacture
In allthese processesattentionof a fitter is required at various
manual effort. The
assembling and testing the finished goods. work benches is
starting from marking to instruments mostly on
on components with hand tools and operations in fitting shop include
Working work'. The hand tools or
Fitting
generally referred to as scraping, drilling, tapping, grinding etc. using hand
components and maintenance
marking, filing, sawing, and inspection of
tools. Measuring technicians.
power operated portable
considered as important work of fitting shop
of equipment is also
Tools:
A) Work Holding work
device commonly used for holding the
1) Bench Vice:- The bench vice is a turned in a clockwise the
moving jaw forces the
handle is handle the
pieces. When the vice pressure applied to the
against the fixed jaw. The greater the is made of cast-iron. Hardened
work The body of the vice
tighter is the work held. gripping of the work are fixed on the
serrationsto ensure better aluminium or
steel plates with made of soft material such as
Jaw caps gripped in
faces of the two jaws. used to protect finished surfacesof the
galvanized iron(G.I.) sheet are held or the
specified by the maximum width that can be
the vice. Vices are to 300mm.
opening between the jaws. Varying from 75mm
maximum
square block with a V
clamp:- The V-block is a rectangular or the V is
2) V-Block with sides, opposite to each other. The angle of securely,
groove on one or both cylindrical work
usually 900. V-block with a clamp is used to hold operation.
measurements or for measuring
during marking of Size: 50 to 150m.
Material C.I. or hardened steel.

Measuring Tools:
B) Marking And flatness of the
The surface plate is used for testing the
1) Surface Plate:- used for marking on
piece and other inspection purposes. It is alsomarking table.
work precise in flatness than the
SImallworks. It is more
 Surface plates are made of C.I. or hardened steel, ground and scraped to
the required precision.Now-a-days surfaceplates 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
400x 100 x grade A has a flatness up to 0.005mm.
2) Universal Scribing 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 etc.
4) Conmbinationset:- A combination set consists of a rule, square head,
centre head and a protractor. This may be used as a rule, a square, a depth
gauge, for marking mitres( oblique ) (45 degrees), for measuring and
marking angles. The rule in made of tempered steel with grooves.

5) Seriber:- Ascriber is a slender steel rod, used to scribe or mark lines on

metal work pieces.
6) Odd-leg caliper:- This is also 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
leg up to the hinge point. Example: 100mm, 150mm etc.

7) Divider:- This is used for marking circles. Arcs laying out perpendicular
lines, bisecting lines, etc. Size ranges from 100mm to 300mm.
small
8) Dot Punch:- This is used to locate centre of holes and to provide a
centre mark for divide point etc. For this purpose, the punch is ground to a
conical point having 60° included angle.
that it is ground
9) Centre Punch:- This is similar to the dot punch, except mark the
It is used to
toa conical point having 90° included angle.drilled. The centre punch mark
location of the centre where holes are to be
accurately.
facilitates easy location of the drill tip and centre
of steel rule to check outside and
10) Calipers:- These are used with the help maximum length
inside mneasurements. They are specified by the
measured. Sizes vary from 100mm to 300mm.
measuring outside as well as inside
11) Vernier Calipers:- These are used for gauge. In the figure
dimensions accurately. It mnay also be used as a depth
 shown, 19 main scale divisions are divided into 20 equal parts in the
division - 1
vernier scale. Hence, least count of the vernier = Imain scale
vernier scale division =1-19/20 =0.05mm.
The size is specified by the maximum measurement it can makeranging
the least
from 150 to 30Omm. The accuracy of the instrument depends on
types of verniers include dial
count, varying from 0.1 to 0.02. Other
vernier, digital vernier with more accuracy etc.
12) Vernier height Gauge:- The vernier height gauge, clamped with a
scriber, it is used for layout work. An offset scriber is used when it is
is
required to take measurements from the surface, on which the gauge
same as
standing. The accuracy and working principle of the gauge are the
those of the vernier caliper. The capacity of the height gauge is specified
can measure. It varies from 150mm to 100Omm.
by the nmaximum height it dimnensions
external
13)Outside Micrometer:- This is used for measuring
accurately. A micrometer of 0 to 25mm range with an accuracy of
different ranges with interchangeable
0.01m1m. These are available in
sizes and 0.01 to 0.001 in
anvils varying from 0.25mm to 200Omm in measure wall thickness of
accuracy. They include thread micrometers to
tubes, etc.

14) Inside Micrometer:- This is used

to measure inside dimensions
of range 25 to 150mm with
accurately, Fig. shows an inside micrometer ranges and accuracies.
different
extension rods. These are available in

C) Cutting Tools:
metal by hand. It consists of a
1) Hacksaw:-The hacksaw is used for cutting number
firmly in position. The blade has a
frame which holds a thin blade, or
cutting teeth. The number of teeth per 25mm of the blade length
of and
the basis of the work material
teeth per inch(TPI) is selected on of hacksaw frames with a blade
thickness being cut shows two types are staggered, as shown which is
blade
fixed. The teeth of the hacksaw
make the slots wider than the blade
known as a 'set of teeth'. This
jamming.
thickness, preventing the blade from
cutting thin
are used for removing surplus metal or for
2) Chisels:- Chisels of octagonal
These tools are made fromn 0.9% to 1.0% carbon steel
sheets. tempered to
are annealed, hardened and
or hexagonal section. Chiselshard cutting edge.Annealing relieves the
produce atough shank and a The cutting angle of the chisel for general
internal stresses in the metal.
purpose is 60 degrees.
 is made of tool steel and is used for
3) Combination cuttimg Plier:- This
The handles of the pliers used by
cutting as wellas for gripping the work. to protect from electric
electricians are insulated with PVCcovering
shocks.
making holes. These are made of
4) Twist Drill:- Twist drills are used for shank twist drills are used with
and taper
high speed steel. Both straight
machines. drills;
sizes and designations of twist
The following are the types,
1) Straight shank
from 0.4mm onwards
Millimetres from 1/64" onwards
Inches
Letter drills A to Z
Number drills 60 to 20

2) Taper shank
3 to 100
Millimetres
1/8" to 4
Inches
hardened steel tool, used for cutting
tap is a in sets
Taps and tap Wrenches:- A hole. Hand taps are usually supplied taper
5) drilling a consists of a
internal threads after thread pitch. Each set
diameter and foilowing are the stages
of three for each bottom tap. The
tap and plug or
tap, interimediate operation. A thread
involved in tapping size tap, with the desired pitch.
correct
1)Select the and pitch.
is specified by its shape, size usually indicated on the tap.
correct size tap drill,
2) Select the
hole.
3) Drill the tap in the tap wrench. and start
4) Secure the taper tap in the drilled hole
pressure.
first or
5)Insert the applying downward axis(verticality)
turning clockwise byofthe tap with the hole applying
alignment necessary, by
6)Check thetry-square and correct it ifthe tap.
with a while turning
sidewise pressure tapping. until
lubricant while and then back
7)Apply tap forward about halfa turnuntil threading is
process
8)Turn the loose. Repeat the taps.
chips break intermediate and bottom work it back and
completed withcarefully.Ifitgets stuck,
them
9)Remove to loosen.
forth gently countersunk, about
snnall
good practice to drillaensure that a base is not
is
Note:1) depth ofone thread to hole.
It
the tapping the
thrown up while
 2) While tapping in a blind hole, remove the tap and clear
of
the chips often so that the tap can reach the bottom
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.
S) Place the die over the chamfered end of the work start cutting threads by
turning it clockwise while applying downward pressure. Apply cutting
fluid while threading in steel.
6) Turn 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
istoo 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 Toois:
1) Files:- Filing is one of the methods of removing small amount of material
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.

2) 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.
Typeof File Description and Use

Hand file:- Rectangular insection and tapered in thickness but

a) teeth and one of the
parallel in width. The faces carry double cut
edge, does not have
edges single cut. The other edge, known as safe safe edge file. It is
any teeth and hence this file in also known as
finished
useful in filing a surface which is at right to an already
surface as in Fig.
length in
b) Flat file:- It is rectangular in section and tapered for 1/3double cut
width and thickness towards the point. The faces carry
teeth and the edges carry single cut teeth. It is a general purpose file.

teeth on all
c) Square file:- It is square in section and carry double cut
the four faces. It is tapered for 1/3 of its length towards the point.
used to
Square files are used for filing corners and slots. It is also
keywaysand slots.

d) 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.

e) Round file:- It istapered 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.
g) 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.
r scellaneous Tools

1) Hammers:- Hammers are named depending on their shape and material and
specified by their weight. A ball peen hammer has a flat face which is used
for general work and the ball end particularly usedfor riveting. They weigh
from 200gm to 1.5kg.
It is
2) Spanners:- A spanner or wrench is a tool for turning nuts and bolts.
usually made of forged steel. There are many kinds of spanners as shown is
application. The size of the
Fig. They are named according to the shape and
can work.
spanner denotes to size of a bolt on which it
designed to turn screws. The blade is
3) Screw drivers:- A screw driver is lengths and diameters. The
made of steel and is available in different important. Screw
shape is very
grinding of the tip of the blade to correct rod. Screw drivers with small
of the steel
driver is specified by the length
connectors. For better grip on screws
which are
rods are known as
diameter screw drivers are
accessible depths, Philips (star )
small and at not easily
used
Practices:
F) Safe and Correct
correct work practices in
some of the safe and
The following are
bench work.

Fitting shop: close to the

that the cut to be made is injury.
the work piece area such Saw breakage and personal
vice.
1) Position practice prevents springing. surfaces in a bench
work of
vice. This
when holding finished
not overhang into aisle
an
2) Use soft
jaws it does
a vice so that brush against it.
3) Positionthe work inperson might
accidentally
suitable for the material
and
where a most
other area hacksaw blade pitch and set, on the
4) Select the cutting operation. stroke, relieve the force
the (cutting)
the nature ofonly on the forward cut. This
Apply force blade bendsds during a
5) return stroke. place when a
in anotherbreakages. cut is to be
Start a nevw
blade
blade corners, where a saw also
6)
prevents bending
and
a file insharp
positioning of the sawand
with
smallgroove permitsaccurate ofwood.
7) Cut a groove twopieces teeth from
The
started. strippingofthe teeth. between
strips, clamp them prevents the saw
prevents metal
thin metal woodandthe
8) Forcutting the
through both themetal.
Cutting bending
diggingin and
 FACE

HEEL

-TANG
>oINT
SHOULDER
TA!L
LENGTH

PARTS oF FILE

60

SINGLE CUTT FLLE

DOUBLE CUT FILE

 JAW-PLATES
movABLE JAW
FLX Ep JAw

NUT

DLE

NDLE

.COLLAR
BENCH VICE

V- BLOCK

SURFACE. PLATE
 [NNERy
MEASURLN G
NLBS L.ocKI NG SCREW
FLNE ASDJUSTIN& UNIT

BEA 0s mALN SCALe

14
tt
2 3 4 5

DE PTH &AUGE

VERNIER
5CAL£ FINE ADJUS TC N &
SCREw

MoVABLE JAW
FLX ED JAW

VERNIER. CALI P£R

CENTRE PUNCH DOT PUNCH

OUTSIDE,
CALTPER
INSLDE CALIPER DIVDER
JENNY/
oDD LEG/
HEMAPHRoDIE
CALIPER
 SET NATION Com3 I
SQUARE TRY
STOCK
BEAM
UAGe SURFACE UNLVERSAL
BASE
PLNS
GUlDE
SE
NUT SPLND
L,E
SCREW
ARm MENT ADJUST
ROcKER
HoLDER SCRIBER
SCRLBER..
5PLNDLE:
 (3)

SlzE OF SQUARE

LENGTH DF SQURE

LENGTH
OF
SH ANK SHANK DAM
Axrs

FLUTE

PLTCH DI A M
" HELX
ANGLE HELEt OF THREAD
THREAD MAJOR DIA
CREST
LENGH
MCNOR DIA.
Ro0T
REAR FLANK

FRONT FANK

CHAMFER.
LENGTH

LAND

CORE DI AM
FLUTE

TAP
 HACKSAW FRAME

HACKsAW
WING NUT

- 0VERALL LENGTH

-NOMLNAL LÊNGTH

PIN HOLE
wwwwm
TEETH
HACKSAW BLADE
BALL PEIN

H EA
ENE HoLE
HANDLE

WEDG¾
PoLL

STRIKING FACE

BALL PEIN HAMMER

 DIAMETER.
HANK,

BACK
TAPER
+
ovERALL BoDY CLEARANCE
LENGTH

DY FLUTE
LENGTH

LAND

FLAN K
CHISEL

CoRNER WEBTHLCKNESs
18°
FACE

PART OF TWIST DRILL