MEC-EPR-211-Bench Work Fitting

UNIVERSITY OF MALAWI
THE MALAWI POLYTECHNIC
ENGINEERING PRACTICE I
(MEC-EPR-211)
BMMP 2 Lecturer:
Moses Kansiya Line
Office: T4B
Line 2021 MEC-EPR-211 2
The term bench work generally denotes
production of work on the bench using hand
tools
Fitting is the process of using tools to prepare
& assemble parts
Preparation of parts for fitting may evolve
removal of material on part by use of file,
chisel, scraper etc. it may also evolve cutting
of part of work using a hacksaw, chisel etc
6
Line 2021 MEC-EPR-211
Work carried out at the fitting bench of a
workshop will depend upon the class of work
for which the shop exists.
The benchwork in a toolroom, or general
engineering shop requires extensive
knowledge & experience (highly skilled
labour).
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Toolroom bench fitting work include
oMarking out, the preparation of work for
machining;
oAdjustment of details after machining; the
building up of jigs, mechanisms & other
assemblies
oMaking & finishing of tools, gauges etc.
oRepair & adjustment of machine tools
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Bench work & fitting in general have important
roles in finishing work to desired accuracy
Bench fitting works include,
oFiling: Using a file
oSawing: Using a hacksaw
oHammering: Using a hammer
oScraping: Using a scraper
oChiseling: Using a chisel
oThreading: Using taps & dies
oEtc.
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This should be a rigid structure normally provided
with racks or shelves at the back for storage of
components or work & tools
It also gives support to a human while performing
various operations, therefore ergonomics must apply
in table height
The bench must not wobble about as one applies
force to a job supported on it. This ensures safety &
production of accurate work
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A bench vice is normally made of an iron or
steel cast body.
The two jaws are faced with hardened steel
jaw-pieces, screwed to the jaws and cut with
teeth to help grip the work.
The sliding jaw is operated by a screw & nut
To avoid damage to the surface of finished
work by the hardened jawpieces, it is usual to
employ clamps (or clams) made of copper,
brass, lead or soft steel.
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In the quick-operating types, the nut only embraces
the lower portion of the screw, being capable of
disengagement from it by the operation of a trigger
at the front of the slide
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Watch YouTube video on bench vice & quik-
release mechanism
https://www.youtube.com/watch?v=nHd6st7Zuv0
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A bench vice is sometimes fitted with a swiveling
mechanism as shown on the diagram below
Swivel
lock lever
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Machine Vice
Pipe Vice
Hand Vice
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A file is a hand cutting tool made of high-carbon
steel, having a series of teeth cut on its body parallel
to each other
Files are used to remove surplus metal in order to
produce a finished surface.
Diagram below shows parts of a file
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There are 6 chief types of files. These are:-
i. Flat file iv. Round File
ii. Hand file v. Half Round File
iii. Square File vi. Three Square/Triangular
Other less commonly used files are:-
vii.Warding file
viii.Pillar File
ix. Mill File
x. Rasp file 20
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Files are of different grades of cut such as
i. Rough Cut
ii. Bastard Cut
iii. Second Cut Bastard Cut
iv. Smooth & Dead Cut
Second Cut
Single Cut
Smooth Cut
Double Cut
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Files may be manufactured in either
o Single Cut: single row of parallel teeth running
diagonally across the face, or
o Double Cut: have two intersecting rows of teeth. The
first row is usually coarser and is called the over-cut. The
other row is called the up-cut. These provide for fast
removal of metal & easy clearing of chips
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i. Flat File:
o // for 2/3 of length, then tapered in width thickness
towards the tip.
o The faces carry double cut teeth while the edges carry
single cut teeth.
o It is a general surfacingpurpose file
ii. Hand File
o Width // throughout but thickness tapers.
o The faces carry double cut teeth. One of the edges is
single cut, the other is the safe edge (no teeth)
o It is useful in filing a surface which is at right angles to
an already finished surface ( for straight & sq. step).
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iii. Square File
o // for 2/3 of length then tapered towards the point.
o It has double cut teeth on all the four faces
o It is used for filing corners & slots i.e.. keyways.
iv. Round File
o It is tapered for 1/3 length similar to sq. file with double
cut on large coarse grades. Single cut on second cut &
smooth cut grades
o Used for filing out round, elliptical & curved openings
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v. Hand Round File:
o It has one flat & one curved side.
o The flat side is double cut & the curved side is single cut
for second cut & smooth cut.
o It is used for flat surfaces & for curved surfaces which
are too large for the round file to be used.
vi. Triangular File
o It is triangular in section & tapers towards the tip.
o The faces are double cut & the edges sharp.
o It is used to file angular hole.
o It is also used for sharpening wood saws.
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vii.Warding File:
o Similar to flat file but thinner & // on its thickness
o It is used for filling narrow slots
viii.Pillar File
o Nearly same as hand file but narrower
o It is used for narrow openings where hand file would not
enter
ix. Mill File:
o Similar to flat file but // on both width & thickness
o One or both edges are rounded for forming radius on saw
teeth & in slots
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x. Horse Rasp File:
o Teeth are cut with a pointed punch
o Faces are partly cut with rasp teeth while the remainder
are ordinary single or cross-cut file teeth
o It is used for filing soft metals, wood soft non-metallic
materials
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Filling is a two hand operation. Always use
two hands
Grip the handle in the palm of the right hand
with the thumb on top. Palm of the left hand
should rest at the point of the file
Gripping the file correctly, stand correctly
close to the vice
Pressure should be applied on the forward
stroke (cutting stroke), release pressure on
return stroke
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Do not lift file from work on return stroke to
avoid curved surfaces
Long steady strokes remove metal faster &
produce a flatter surface
Use smooth cut files for finishing work
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Filing is in two forms
i. Cross Filing: In cross filing, push the file across
the work face in a straight line by movement of
the right arm from the shoulder. It is used to
produce a flat surface,
ii. Draw Filing: When draw filing, hold the file
across length of work & move file back & forth
close & away from you) along the length of the
work. It removes file marks & scratches left by
cross-filing. It is used to produce a smooth, flat
surface on the work piece.
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Holding a File for Heavy Work Holding a File
Draw Filling
Cross Filling
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Cross Filling Draw Filling
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When filing broad surfaces, the handle would
prevents full stroke of the file
 A file holder is used to clamps the tang of the
file
Surfaces produced in this way are generally
finished flat by scraping
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 The teeth of files may clog with minute
pieces or chips of metals – This is called
pinning
 if the file is not cleared this accumulation
will not only stop the efficient cutting
action, but also scratch the work.
 A file card is used to remove pins which
are firmly held
 A file card is a brush made from a strip of
webbing having thin, hard wire bristles
 Tightly-wedged pins must be scraped out
with the point of a scriber
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i. Avoid files rubbing against each other. Hang
or store them separately.
ii. Never use a file as a pry or a hammer.
iii. Do not knock a file on a vise or other
metallic object to clean it. Always use a file
card or brush for this purpose.
iv. Apply pressure only on the forward stroke
when filing. Pressure on the return stroke will
dull the file.
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v. If the file is completely chalked, use
turpentine to clean it
vi. For surfaces of unknown hardness or of
casting or of welded joint, do not use a new
file
vii.Start with a new file for brittle materials i.e.
cast iron & brass
viii.Shamfer edges of cast iron of black scaly
condition before actual filing to avoid
damage to file teeth
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A hacksaw is used for
sawing or cutting on
most metals, wood,
plastics etc.
It consists of a handle,
frame & blade which
may be tightened by
screw & nut.
Frames can be in solid
form or adjustable
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The most usual blade for hand work is 300 mm long
by 12 mm wide.
Blades may be of carbon or high speed steel
Blades may be finished either with the cutting edge
only hardened (flexible type), or they may be hard
right through (all hard or solid type).
The soft-backed or flexible blades are tougher &
less liable to snap than the all-hard blades, but are
not as efficient.
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 Solid blades are used on brass, tool
steel, cast iron, & larger sections of
mild steel, since they do not run
outof line when pressure is applied.
 Flexible blades may be used on
channel iron, tubing, copper, &
aluminum, since they do not break as
easily on material with thin cross
sections.
 The teeth of the hacksaw blade are
staggered to make the slots wider
than the blade thickness, preventing
the blade from jamming.
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Breakage of blades may be caused by the
following:
o Rapid & erratic strokes,
o Too much pressure,
o Blade held too loosely in the frame,
o Binding of the blade from uneven cutting,
o Work not held firmly in the vise.
Insufficient pressure at the start of a cut may
cause the teeth to glaze the work, & so rub
their edges away.
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Blades are manufactured in various pitches (number
of teeth per inch), such as 14, 18, 24, & 32.
The pitch is the most important factor to consider
when selecting the proper blade for a job.
An 18-tooth blade is recommended for general use.
Choose as coarse a blade as possible to provide
plenty of chip clearance & to cut through the work
as quickly as possible.
The blade selected should have at least two teeth in
contact with the work at all times
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The hammer is probably the most used of all
the fitting tools
The most common type of hammer is the ball-
peen hammer
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Hammers are specified by the shape of the end
opposite the striking face, called the pein.
i. The ball pein: is the most common of the
three, the ball end, being used mostly for
riveting over the ends of pins and rivets.
ii. Cross and straight peins: are also useful for
riveting in awkward places; another use
Another use for these ends is that of peening
(to stretch & elongate work).
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Hammer heads are made from a plain steel of
about 0·63 carbon & are shaped by stamping
or forging.
The ends are hardened & tempered, the centre
of the head, with the eye, being left soft.
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Engineers' hammers are made in weights
varying from 1/8 kg to 1 kg
The most commonly used hammers range
from 1/4 to 1/2 or 1 kg.
Light hammers are used for lighter & more
delicate operations such as
olight riveting,
ostriking centre punches and small chisels,
odriving in small pins, etc.
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Heavy heads are necessary for
oheavy chipping,
odriving pulleys & collars on to shafts,
odriving large pins & shafts into holes, etc.
Energy spent in blowing is given by
Note that work is a product of force &

distance moved
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They must be of well-seasoned, straight-
grained hickory or ash, free from knots or
other defects.
They should be of a size & length suited to the
size of the head,
They must be shaped to suit the eye it will be
secured to with a hardwood wedge.
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They are used where a hardened head or pein
would bruise or mar a finished surface.
The chief soft hammers used have heads of
oRawhide: made of cast iron into which
plugs of rawhide are inserted
oCopper or aluminium: made of copper or
aluminium
oLead: made of lead cast on to steel tube
oPlastic: made of plastic
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1. A hammer of mass 0.5 kg moving at 1 metre per second
strikes a pin & drives it a distance of 3 mm. Estimate the
average force of the blow.
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i. Handle must be solid & not cracked
ii. Head must be tight on the handle & secured
with a proper wedge
iii. Never use a hammer with a greasy handle
or hand
iv. Never strike two hammer faces together.
The faces are hardened & a metal chip may
fly off, causing an injury.
59
Chisels are used for removing surplus metal or
for cutting thin sheets
Engineers’ chisels are distinguished from other
chisels by the fact of their not having a
wooden handle.
61
Common chisels are made from cast tool steel
of octagonal cross-section,
The heaviest chisels are made from about 20
mm material
The smaller chisel sizes are from lighter
section steel down to about 10 mm.
Alloy tool steels may also be used for chisels.
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The four most important types of chisel are
i. Flat Chisel
ii. Cross-cut Chisel,
iii. Half-round Chisel &
iv. The diamond chisel
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Commonly made in heaviest
form of about 200 mm long,
Lighter sizes are proportionately
shorter.
It is tapered & flattened for
about one-third of its length to
the cutting edge
After forging to shape &
roughly grinding, the chisel
edge should be hardened &
tempered 64
The cutting end of this chisel
is forged as shown
Cutting edge AB being 6 mm
to 9 mm wide. From edge, it
tapers off slightly, being
slightly thinner at CD.
It is for cutting grooves across
the faces of surfaces which
required to be finished off flat
i.e. keyways, slots, etc.
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 It is half round in profile as
shown
The half round pattern is
useful for cutting grooves
i.e. oil grooves in bearings
& similar work.
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It has a profile of a diamond
It is often used for cutting
holes in plates i.e. boiler
plates
It is also for grooving the
start of a drilled hole to
correct for an error in the
starting of the drill.
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Scrapers are used to remove surplus material where
work renders grinding impossible
The purpose of the scraper is to correct slight
irregularities
Scraping is a laborious process
Hold scraper handle in the right hand & press on the
scraper with the left hand then make strokes
Apply less pressure on return stroke
Keep scraper sharp
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 The main two types of scrapers are flat scraper & half round
scraper
It is for flat surfaces.

Sometimes it is made from old flat file
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It is for internal cylindrical surfaces i.e. finishing of
cylindrical bearings for bedding in the shaft.
Sometimes made from old half round file
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Threads may be cut by hand (manually)
i. Internally using a tap &
ii. Externally using a die
Solid Die
Taps 73
Taps are cutting tools used to cut internal
threads.
They are made from high quality tool steel,
hardened & ground
Flutes are cut lengthwise across the threads to
provide room for the chips & cutting fluid to
The end of the shank is square for insertion of
a tap wrench
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Taps are cutting tools used to cut
internal threads.
They are made from high quality
tool steel, hardened & ground
Flutes are cut lengthwise across
the threads to provide room for
the chips & cutting fluid
The end of the shank is square
for insertion of a tap wrench
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For metric threads, a tap with the markings M4—0.7
indicates:
o M means a metric thread
o 4 is the nominal diameter of the thread in
millimeters
o 0.7 is the pitch of the thread in millimeters.
TDS = D - p
where D is the major diameter in mm & p is the
pitch in mm.
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Tapping is the operation
of cutting an internal
thread using a tap & tap
wrench
Care must be taken to
avoid breaking taps as
they are hard & brittle
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i. Select the correct size tap, i.e. M20 × 2.5
ii. Select the correct TDS,
iii. Drill the hole.
iv. Secure the tap in the tap wrench.
v. Insert the first or taper tap in the drilled hole start
turning clockwise
vi. Ensure squareness between tap & work.
vii. Turn the tap forward about half a turn & then back until
chips break loose. Repeat the process while applying
lubricant.
viii. Finish tapping with intermediate & bottom taps.
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Threading dies are used to cut external threads on
round work.
The most common threading dies are
i. Solid Die: is not adjustable. for chasing or re-cutting
damaged threads
ii. Adjustable Split Die: permits an adjustment over or
under the standard depth of thread. This type of die fits
into a die stock
iii. Adjustable Screw Plate Die: provides for greater
adjustment. Two die halves are held securely in a collet
by means of a threaded plate, which also acts as a guide
when threading.
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Solid Die Adjustable, Round
Nut Split Die
Adjustable Screw Plate Die
Die Stock 82
Die Stock
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i. Fasten the work securely in a vise.
ii. Select the proper die & die stock.
iii.Lubricate the tapered end of the
iv. Place the tapered end of the die squarely on the
work piece
v. Press down on the die stock handles, turn
clockwise several turns. Check that it has started
squarely with the work.
vi. Turn the die forward one turn & then reverse.
Apply lubricant
vii.Adjust die is adjustable & complete threading.
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A tap extractor can be used to
remove a broken tap
The tap extractor is a tool that has
four fingers that slip into the flutes
of a broken tap.
A tap extractor can be adjustable
in order to support the fingers
close to the broken tap
A wrench is fitted to the extractor A = Slide Collar
& turned counterclockwise to B = Body (down)
C = Slide Collar
remove a right-hand tap.
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Sometimes an acid can be used to remove a
broken tap if it is made of high-speed steel &
cannot be removed with a tap extractor, it is
sometimes possible to remove it by the acid
method.
Others use a tap disintegrator which uses the
electrical discharge principle to cut its way
through the tap, using a hollow brass tube as an
electrode.
If the tap is made of carbon steel, it may be
possible to drill out the broken tap
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UNIVERSITY OF MALAWI

THE MALAWI POLYTECHNIC

Note that work is a product of force &

It is for flat surfaces.

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