3.

Study of Fitting Joints, Tools and Equipments

Aim
To study the various Fitting process, tools and equipments.
Introduction
Fitting is the process of assembling together of parts to get the necessary fit. Some
operations do not require the use of machines. Example : filing, stamping, chipping,
sawing operations.
The shop where these operations are carried out is called the fitting shop. An
operator who does the fitting work is called fitter. To perform fitting operations various
tools are needed. So, the fitter must know the various fitting tools specification and its
usages.

Fitting Tools
The tools used in the fitting shop are classified into the following groups.

Holding Tools
The Holding tools are used to hold the work piece during fitting operations. The
different types of holding tools are discussed below.

Bench vice

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Bench Vice
It is used to hold work piece during cutting, drilling, threading and other such
related operation. It consists of a fixed jaw and a movable jaw with a screw handle for
adjusting these jaws. The width of jaws varies from 80mm to 180mm.
Hand Vice
Hand vice consists of two jaws. The jaws are hinged and pivoted to the opposite
ends. The work is held between the jaws. It is used for Holding light works only.

Pipe Vice
Pipe to be cut or threaded must be held steadily and prevented from rotation by
holding them so far this pipe vice is specially designed to hold cylindrical objects.

Pipe Vice
C Clamp
‘C’ clamp is used to hold work piece against an angle plate. It is made up of
malleable iron.

Striking Tools or Hammers

Hammers are made of high carbon steel. They are used for striking nail, rivets,
punches, chisels, etc. It consists of a head, peen, striking face and handle. According to
shape and weight of hammer, they are classified into the following types.

Ball Peen Hammer

One side of the ball peen hammer is flat and the other side is spherical in shape.
It is used for rounding – off rivets, making round and concave indentations and also for
flattening the surfaces.

Ball Peen Hammer Cross Peen Hammer

Ball Peen Hammer Cross Peen Hammer
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 Straight
Straight Peen Hammer
Peen Hammer Sledge
Sledge Hammer
Hammer

Mallet Claw Hammer

Marking and Measuring Tools

A work that has to be marked and measured is carried out by the following tools.
Some of the marking and measuring tools and their uses are discussed below.
Steel Rule
It is a liner measuring tool usually available at lengths of 150mm and 300 mm
measured both in mm and inches. It is made up of tempered rust free steel or stainless
steel. The least count of steel rule is 1mm.

0 cms 1 2 3 4 5 6 7 8 9 10 11 12

Steel Rule

Inside Caliper Outside Caliper

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Calipers
Calipers are used for measuring curved surfaces. There are two types of calipers
namely, inside caliper and outside caliper.
)) Inside caliper is used to measure the outer diameter of pipe.
)) Outside caliper is used to measure the inner diameter of pipe.

Vernier Caliper
It is made of steel. It is used for measuring inside, outside diameter and depth of
work piece. The Least count of vernier caliper is 0.02mm.

Vernier Caliper

Scriber
It is made of carbon steel has sharp pointed edge. It is used to scribe the work piece.

Scribers

Try Square
Try square is used for marking and testing right angles. It consists of a steel blade

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riveted at right angle to the edge of the machined stock. The blade length varies from
150mm to 300mm.

Try screw
Dot Punch
It has conical points with an angle 60°. It is used to make dots along marked line
on the work piece.

Dot Punch Centre Punch

Centre Punch
The point of the punch is made to 90°. It is used to mark a drill point on the work
for seating the drill bit for drilling operation.
Cutting Tools
The operation such as chiseling, sawing, chipping; filing and scraping are carried
out using cutting tools. Some of the cutting tools are described below.
Chisels
It is made of high carbon steel. It has a sharp wedge shaped cutting edge. The
cutting action is done by hitting its head with hammer. The cutting edge is
sharpened and hardened. The chisels are classified according to the shape,
length, width and cutting edge.

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 Cold Cape Round Nose Diamond point
Chisel Chisel Chisel Chisel

Types of Chisels
Cold Chisels
It is a commonly used chisel in fitting shop. It is used for cutting cold metals.
The cutting edge is slightly curved shape and its cutting angle is 60°. The width of the
cutting edge varies from 20 to 25mm and its length varies from 100 to 400mm.

2. Hacksaw
Hacksaw is a hand tool used by the fitter for cutting operations. It has two
parts namely the frame and a blade. One end of frame is fixed type and the other is an
adjustable type, between the frame grooves the blade is locked.

Hacksaw
Types of blade according to size
1. Coarse blade : 14 tooth per inch (for soft metal).
2. Medium blade : 22 tooth per inch (for medium hard metal).
3. Fine blade : 35 tooth per inch (for hard metal).

Types of blade according to hardening

1. Fully hardened blades
2. Flexible blades
3. High speed steel blades

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 Hacksaw Blade
Finishing Tools
Finishing tools are used to remove burrs and clean outer surface of the workpiece.
The best example for finishing tool is files, abrasive paper.

Parts of a File
Files
This is a widely used finishing tool in fitting shop. Files are made of hardened steel
having parallel rows of teeth through out its surface.

Parts of a File
Tang It is a pointed part fixed on a wooden handle.
Point It is the opposite edge to the tang.
Heel It is the face of file that comes next to the tang.

Classification of Files
Files are classified according to the following factors.
Fitting Process
There are several fitting operations performed on a workpiece to get required size,
shape and fit. The following operations are performed in a fitting shop.
1. Measuring, marking 5. Chipping
2. Sawing 6. Drilling
3. Filing 7. Reaming
4. Scraping 8. Tapping

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 Various shapes of files per cross section

Safety Precautions in using Tools

1. Use right tools for the right job.
2. Always keep the tools in their prpper place.
3. Always use the file with handle.
4. Hacksaw blade should be fitted on the frame perfectly.
5. Use always safety goggles while chipping.
6. Always keep the files in a simple wooden rack
7. Remove the oil from the file before starting the filing operation.
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Safety Precautions in fitting Shop
1. Keep the fitting area clean.
2. Wear safety devices like goggles, apron clothes and footwear.
3. Don’t run inside the shop.
4. Keep the oil, grease away from the workshop.
5. The job should be properly fitted in the vice.
6. Work in a well lightened space.
7. Do not touch the chip, while it comes out of the work piece.
8. The machines should be operated only after getting the permission from the
workshop in charge.
9. Do not wear loose clothes.
10. Does not use file as a hammer?

Mark Allocation
S. No. Particulars Marks Allotted Marks Awarded

1 Aim, Procedure and Diagram 10

2 Execution 15

3 Calculation, Graph and Result 15

4 Viva Voce 10

Total 50

Signature of the Faculty with Date

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Square Fitting

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 Ex. No. : ....................
Date : ....................
Square Fitting

Aim
To file the given MS piece into a square shape of 48mm side

Tools Required
1. Bench vice 5. Scriber
2. Steel rule 6. Dot punch and rough
3. Try-square 7. Smooth flat files with safe edges
4. Ball-peen hammer

Procedure
1. The dimensios of the given piece are checked with the steel rule.
2. The job is fixed ridigly in a bench vice and the two adjacent sides are files,
using the rough flat file first and then smooth flat file such that, the two sides
are at right angle.
3. The flatness of the two adjacent sides is checked with the try-square.
4. Chalk is then applied on the surface of the workpiece.
5. The given dimensions are marked by scribing two lines, with reference the
above two datum sides.
6. Using the dot punch, dots are punched along the above scribed lines.
7. The two sides are then filed, by fitting the job in the bench vice ; followed by
checking the flatness of the surfaces.

Viva Questions
1. Define fitting process
2. Classify the tools used in fitting shop
3. List the holding tools used in fitting process
4. Infer the use of C clamp
5. Explain the use of V block

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12
 All dimensions are in mm

Result
A square piece of 48 mm side is thus obtained by filing, as discussed above.

Mark Allocation
S. No. Particulars Marks Allotted Marks Awarded

1 Aim, Procedure and Diagram 10

2 Execution 15

3 Calculation, Graph and Result 15

4 Viva Voce 10

Total 50

Signature of the Faculty with Date

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TEE - Fitting

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Ex. No. : ....................
Date : ....................
TEE - Fitting

Aim
To make a Tee fitting from the given workpieces.

Tools Required
1. Bench Vice 7. Jenny Caliper
2. Hammer 8. Surface Plate
3. Try Square 9. Steel Rule
4. Angle Plate 10. Fixed Hacksaw
5. Dot Punch 11. Vernier Height Gauge
6. Files

Procedure
1. The given workpiece is first checked for its size using steel rule. After that it
is clamped in the bench vice and two adjacent sides are filed using a flat file
so that workpiece is made at right angle.
2. Cut the workpiece into two pieces using hacksaw.
3. Chalk is applied on the surface of the work piece for marking.
4. With the finished face as reference, the required dimensions are marked on
the workpiece with the use of Surface plate, Vernier height gauge, Jenny
Caliper and Steel rule. Then these markings are made clear by punching dots
on it using dot punch.
5. All the above said operations are carried out in both the workpieces.
6. Then using Hacksaw the unwanted portions are removed.
7. The cut faces are then smoothened and polished using smooth flat and
triangular files.
8. Finally, the workpieces are fitted to form a tee fitting.
Viva Questions
1. Infer the material used to make the hammers
2. Mention the criteria’s used to classify the hammer
3. List out the hammers used in fitting shop
4. Difference between ball peen hammer and cross peen hammer
5. Illustrate the use of mallet

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16
 All dimensions are in mm

Result
Thus, the required Tee fitting is obtained from the given work pieces.

Mark Allocation
S. No. Particulars Marks Allotted Marks Awarded

1 Aim, Procedure and Diagram 10

2 Execution 15

3 Calculation, Graph and Result 15

4 Viva Voce 10

Total 50

Signature of the Faculty with Date

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V - Fitting

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 Ex. No. : ....................
Date : ....................
V - Fitting

Aim
To make a V-joint on the given workpieces.

Tools Required
1. Bench Vice 7. Jenny Caliper
2. Hammer 8. Surface Plate
3. Try Square 9. Steel Rule
4. Angle Plate 10. Fixed Hacksaw
5. Dot Punch 11. Vernier Height Gauge
6. Files

Procedure
1. The given workpiece is first checked for its size using steel rule. After that is
is clamped in the bench vice and two adjacent sides are filed using a flat file
so that workpiece is made at right angle.
2. Chalk is applied on the surface of the work piece for marking.
3. With the finished face as reference, the required dimensions are marked on
the work piece with the use of Surface plate, Vernier height gauge, Jenny
caliper and Steel rule. Then these markings are made clear by punching dots
on its using dot punch.
4. Cut the workpiece into two pieces using hacksaw.
5. All the above said operations are carried out in both the workpiece.
6. The using Hacksaw the unwanted portions are removed.
7. The cut faces are then smoothened and polished using smooth flat and
triangular files.
8. Finally, the assembly is checked for the required Vee fitting.

Viva Questions
1. Explain the use of claw hammer
2. List the different types of calipers
3. Examine the marking and measuring tools used in fitting
4. Infer the material used to make scriber
5. Discuss advantage of thumb screw in divider

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20
 All dimensions are in mm
Result
Thus, the required V-joint is obtained from the given work pieces.

Mark Allocation
S. No. Particulars Marks Allotted Marks Awarded
1 Aim, Procedure and Diagram 10
2 Execution 15
3 Calculation, Graph and Result 15
4 Viva Voce 10
Total 50

Signature of the Faculty with Date

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Dovetail Fitting

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 Ex. No. : ....................
Date : ....................
Dovetail Fitting

Aim
To make a dovetail fitting from the given two MS pieces.
Tools Required
1. Bench vice 7. Ball-peen hammer
2. Set of files 8. Hacksaw with blade and
3. Steel rule 9. Scriber
4. Surface plate 10. Flat chisel
5. Try-square 11. Dot punch
6. Jenny caliper
Procedure
1. The burrs in the given pieces are removed and the dimensions are checked
with the steel rule.
2. The pieces are clamped one after the other and the outer mating edges are filed
and checked for their flatness, with the help of the try-square.
3. The side edges of the two pieces are filed such that, they are right angle to
each other and widths are exactly 48 mm.
4. Chalk is then applied on the surfaces of the two pieces.
5. The given dimensions of the dovetail fitting are marked, by using the Jenny
caliper, steel rule and surface plate.
6. Using the dot punch, dots are punched along the above scribed lines.
7. Using the hacksaw, the unwanted portions are removed.
8. Using the flat chisel, the unwanted portions are removed.
9. The cut edges are filed by the half round file.
10. The corners of the stepped surfaces are filed by using a square or triangular
file to get the sharp corners.
11. The pieces (X and Y) are fitted together and the mating is checked for the
correctness of the fit. Any defects noticed, are rectified by filing with a smooth
file.
Viva Questions
1. Differentiate dot punch and center punch
2. Name the cutting tools used in fitting process
3. Classify the chisel based on with of the cutting edge
4. List the types of blades according to size
5. List the types of blades according to hardening
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24
 All dimensions are in mm

Result
The required dovetail fitting is thus obtained, by following the stages as described
above.

Mark Allocation
S. No. Particulars Marks Allotted Marks Awarded

1 Aim, Procedure and Diagram 10

2 Execution 15

3 Calculation, Graph and Result 15

4 Viva Voce 10

Total 50

Signature of the Faculty with Date

25
5. Half Round Fitting

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Ex. No. : ....................
Date : ....................
5. Half Round Fitting

Aim
To make a half round Fitting from the given two MS pieces.
Tools Required
1. Bench vice 6. Surface plate
2. Dot punch and centre punches 7. Ball-peen hammer
3. Steel rule 8. Jenny caliper and
4. Set of files 9. Spring divider
5. Try-square 10. Hacksaw with blade

Procedure
1. The burrs in the given pieces are removed and the dimensions are checked
with the steel rule.
2. The outer mating edges are files, by rigidly fixing in the bench vice. The
flatness of the edges is also checked by the try-square.
3. The side edges of the two pieces are filed such that, they are right angle to
the edges and the widths are exactly 48 mm each.
4. Chalk is then applied on the surfaces of the two pieces.
5. The given half rounds (semi-circles) are marked on the two pieces, by using
the Jenny caliper, and spring divider.
Note : The centres of the half rounds are marked by a centre punch However, after
marking the centre of the half round in the piece Y the edge of it is further filed, till half of
the punch dot is left.
6. Using the dot punch, dots are punched along the above scribed lines.
7. Using the hacksaw, the unwanted portions are removed to the extent possible.
8. Using the flat chisel, the unwanted portions are removed.
9. The cut edges are filed by using square and half round files.
10. The pieces (X and Y) are fitted together and the mating is checked for the
correctness of the fit. Any defects noticed, are rectified by filing with a smooth
file.

Viva Questions
11. Explain the major parts of file
12. Classification of files based on their shape
13. Classification of files depending on cutting of tooth
14. Differentiate single cut file and double cut file
15. Write the advantage of dead smooth cut file

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28
 All dimensions are in mm

Result
The required dovetail fitting is thus obtained, by following the stages as described above.

Mark Allocation
S. No. Particulars Marks Allotted Marks Awarded

1 Aim, Procedure and Diagram 10

2 Execution 15

3 Calculation, Graph and Result 15

4 Viva Voce 10

Total 50

Signature of the Faculty with Date

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 Stepped Joint

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 Ex. No. : ....................
Date : ....................
Stepped Joint

Aim
To make a stepped-joint on the given workpiece.

Tools Required
1. Bench Vice 7. Jenny Caliper
2. Hammer 8. Surface Plate
3. Try Square 9. Steel Rule
4. Angle Plate 10. Fixed Hacksaw
5. Dot Punch 11. Vernier Height Gauge
6. Files

Procedure
1. The given workpiece is first checked for its size using steel rule. After that is
is clamped in the bench vice and two adjacent sides are filed using a flat file
so that workpiece is made at right angle.
2. Chalk is applied on the surface of the work piece for marking.
3. With the finished face as reference, the required dimensions are marked on
the work piece with the use of Surface plate, Vernier height gauge, Jenny
caliper and Steel rule. Then these markings are made clear by punching dots
on its using dot punch.
4. Cut the workpiece into two pieces using hacksaw.
5. All the above said operations are carried out in both the workpiece.
6. The using Hacksaw the unwanted portions are removed.
7. The cut faces are then smoothened and polished using smooth flat and
triangular files.
8. Finally, the assembly is checked for the required stepped joint.

Viva Questions
1. List the operation performed in fitting shop
2. Define the process filing
3. Mention the parameters considered to choose the filing method
4. Classify the filing methods
5. Illustrate the application of fitting

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32
 All dimensions are in mm

Result
Thus, the required stepped-joint is obtained from the given work piece.

Mark Allocation
S. No. Particulars Marks Allotted Marks Awarded

1 Aim, Procedure and Diagram 10

2 Execution 15

3 Calculation, Graph and Result 15

4 Viva Voce 10

Total 50

Signature of the Faculty with Date

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