MUHAMMAD HAFFIZ AIMAN BIN YAHAYA 1

11DKM19F1029

DJJ1032
FITTING
(HEXAGON GAUGE)

MUHAMMAD HAFFIZ AIMAN BIN YAHAYA

11DKM19F1029

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INTRODUCTION

Fitting refers to the mating of two mechanical components.

Manufactured parts are very frequently required to mate with one
another. They may be designed to slide freely against one another
or they may be designed to bind together to form a single unit. The
most common fit found in the machine shop is that of a shaft in a
hole.

Hand tools are important in fitting work. Furthermore, knowing how is

important to prevent damages of the tools and keep the tool life longer marking
is to obtain shape on work piece to the design given in the drawing. It serves as
guide to forming operator. Drilling is a process of making a hole on the work
piece. A hole need to be drill before tapping is called tap drill size.

TAPE DRILL SIZE(TDS) = DIAMETER OF BOLT - PITCH SIZE

Tapping is a process of making a thread in a hole after drilling. A reamer is a

side cutting tool used for accurately finishing the straight or tapered holes
already drilled or bored.

TASK OUTCOME

1) Practice correctly safety procedures in the workshop.

2) Carry out fitting work with various hand tools, marking out, measuring tools,
testing tools and drilling machine.

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EQUIPMENTS

1. Mid steel plate (50mm X 100mm)

2. Steel ruler

Function

 To measuring workpiece in cm, mm and

inch.

3. Scriber

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Function
 used in metalworking to mark lines on
workpiece, prior to machining.

4. Divider

Function

 Used for making circle on material and for

geometric development.

5. L square or engineering square

Function
 Used to get 90’ angle of workpiece.

6. Vernier height gauge

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Function
 Used to measure height of the workpiece at flat
surface
7. Granit surface plate

Function
 used for tool making, inspection, spotting,
gauging etc.

8. Angular plate

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Function
 used as a fixture in metalworking.

9. Vee block
Function

 used to hold round metal rods or pipes for

performing drilling or milling operations.

10.Mechanical protector

Function
 Used to measure angle in degrees (‘).
11.Working table with vise

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Function
 Used to hold workpiece while files.

12.Files

Function
 Used to thinning the workpiece thickness

13.Hack saw

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Function
 Used for cutting metal, but can also cut various
other materials, such as plastic and wood.

14.Bench Drill

Function

 used for drilling holes through materials

including a range of woods, plastics and metals

15.Drill Bits

Function
 used to drill metal, hardwood, and most other
materials.

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16.Hammer

Function
 used to drive nails, fit parts, forge metal, and
break apart objects.
17.Chisel

Function
 used for cutting or carving hard materials such
as metal, stone or wood.

18.Centre punch

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Function
 used to mark the center of a point. It is usually
used to mark the center of a hole when drilling
holes.

19.Vernier caliper

Function
 Used measure to an accuracy of one thousandth
of an inch and one hundredth of a millimeter
20.Micrometer

Function
 used for the precise measurement of very small
objects.

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21.Threading tap

Function
 Set to cut or form the male portion of the
mating pair (e.g. a bolt).\

22.Reamer

Function
 Used to enlarge the size of a previously formed
hole by a small amount but with a high degree
of accuracy to leave smooth sides

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SAFETY PRECAUTIONS
-Keep proper discipline in the shop
-Do not play with the tools because they are sharp
-All files should be fitted with suitable handle at end of file.
-When using Hacksaw, check its teeth should be sharp and forward
position
-When using chisel its direction should be kept away from other
working persons.
-When files are of forward cut, and then only apply the force in
forward stroke not in backward and vice versa.
-When using Hacksaw check its blade with must be fitted in pins
properly.
- Clean up oil and grease or other liquid which spills on the flour
otherwise they may be a cause of accident.
-Do not wear any neck tie, jewelers, rings, and watches during in
the working in shops

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PROCEDURE

1. Use file to remove the iron chips from the plate edge and make the edge flat
90’ (easy to do layout marking and measurement as datum).
2. Make the layout given on the plate by using steel ruler and scriber or Vernier
height gauge on the grant it surface plate and angular plate.
3. Draw the hexagon using the divider (make a circle), mechanical protector
(mark a straight line outside the circle), steel ruler and scriber (join the edge
to become hexagon shape)
4. Use the centre punch and hammer to mark the centre of the point to be drill.
5. Start sawing the plate using hacksaw on the working table and clamp the
plate on the vise tightly.
6. Choose the suitable bits to drill on the plate. Clamp the plate on the vise
tightly, wear goggle to protect eye from flying chips while drilling, use coolant
while drilling to avoid the plate and the drill bits no overheated (the first hole
use 8.5mm diameter of the drill bits, the second hole use 9.5 mm diameter
drill bits. For drilling the hole in hexagon shape, use 3 mm diameter drill bits,
drill around the hexagon shape for easy removing by chisel).

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7. Use hammer and chisel to remove the centre of the plate (the hexagon
shape).
8. Use various type of files to make the hexagon shape better looking.
9. Use threading tap to make inner threading at one of the hole (8.5 diameter).
10. Use reamer to make another hole exactly 10 in diameter.
11. Do filling on the plate to get the shining surface and make the plate thinner
as 4.5 mm.
12. Put some oil on the surface to prevent the plate from rust or corrosion.

DISCUCSSION
In 5 weeks in the workshop I do a project with hand tools. Many type of problem I
had through, but with lecturer helps and instructor, me and my friend, trough the
problems smoothly and success. However, our workpiece complete, we find out that
many defects on our workpiece. Therefore, we listed all the defects on our
workpiece.

CONCLUSION

In my conclusion, we must make this work according to the rules and instruction
of the lecturer that this work is dangerous if we make it without the rules. This work
also very tired and we must use a lot of energy. We also must be careful and focus
current doing process this project because want exact size, right angle and
nervousness.

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REFERENCE
1. http://slideshre.com/hexsagongauge
2. http://scribd.com/safetyprecaution
3. http://Wikipedia.com/handstoolfunction
4. http://googleimage.com

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