10.

01

M 12. BENCH FITTING& FABRICATION:

-Use of Hand Tools & Tackles
Engr. Rahul Islam
Executive Engineer (Mech.)
1.0INTRODUCTION
A bench fitting is a mechanical job work done using a work bench to hold the job Dy
vice and the operation with normal hand tools. Engineering fabrication is simply
manufacturing parts that have been designed
To do so, it is necessary to some parts sawing, filling, threading, hammering etc.

In broad sense, bench fitting involves the following operations

- Hammering - Sawing - Drilling
- Marking - Chipping - Punching
- Reaming - Filing - Threading, etc.

2.0 HAND TOOLS, TYPES AND THEIR USE:

2.1 Hand tools:
A tol which is powered by human muscle rather than a motor or engine is knovwn
a hand tool. Hand tools are generally less dangerous than power tools.
To get best output from the tools, the following three rules should always
remembeer
Purchase only qualitative tools
Keep tools in safe condition
Use the right tool for the job
2.2 Types of Hand tools:
Hand tools fall into two major groups and each group of hand tools includes a number
of tools relates to a number of bench work processes:-
A. Non cutting hand tools &
B. Cutting and shaping hand tools

A. Non cutting hand tools

The hand tools, which are used to other than cutting work, are known as non-
cutting hand tools. There are three types of tools in this group
Hammering tools
Fastening tools&
Clamping tools

Hammering tools
Hammer:
Hammer is used to deliver a flat blow (force) or to shape and form metal
The flat face is for hammering and the peen part for riveting and similar job.
Hammers come in many types, sizes and shapes.
Hammers are two types according to their material:
Steel hammer Soft faced hammer

Three types of steel

hammer are used in
machine and metal trades:
Ball-peen hammer
Straight-peen hammer Straight-peen Cross-peen
Ball-peen Hammer Hammer
Cross-peen hammer. Hammer

Mechanical Engineering Department, TICI,Polash, Narsingdi-1611

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Soft faced hammers are

used in assembleand
disassemble operation
in LGAD

place of steel hammer to

protect machined surface or
PEA
fragile parts. Soft hammer
are commonly made of:-
Lead Plastic Brass unCTiIANE COMPOSI1I

Rawhide "Rubber "Urethane composition:

Use:
Always grip the hammer close to the end of the handle to increase leverage for
a harder blow.
Whenever possible strike the object squarely with the full face of the head to
prevent damage to the hammer face and to the object.

Fastening tools
Screwdriver
Hand wrench

Screwdriver:
Screwdrivers are used to install and remove
Among many types the most common types threaded fasteners.
of screwdriver are:
Flat head screwdriver
Phillips-head or cross head screwdriver
Offset screwdriver
HANDLE

Flat head screwdriver Phillips head serewdriver offset serewdriver

Use:
The working people should select a tip size that is almost the width and length
of the screw slot.
The tip of the blade should be flat so that it can be held firmly against the
bottom of the slot.

Hand wrench:
Like screwdrivers, hand wrenches are also considered to be fastening tools.
The opening or closed space of wrench designate the size of wrench in inches
or millimeter.
The most common hand wrenches are:
Open-end wrench Socket wrenchh
Adjustable open-end wrench Set screw or allen wrench
Box wrench Torque wrench
Pipe wrench Hook Spanner

OX RENCH
Open end wrench Box wrench

ADUSIM SCRE
Adjustable open end wrench Pipe wrench

Mechanical Engineering Department, TICI, Polash,

Narsingdi-1611
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HEAO

DHVE BOUAR
CINTEA
SCAUE

&LEMENT

PIVO ED ANDLE
soCKET-
BEAM TYPE

Socket wrench
Torque wrench

St:1 $t RE WPENCt

HEADLESS

Set screw or allen wrench Hook Spanner

Use:
B e sure that wrench correctly fits the nut or bolt.
Always pull in a wrench don't push
If you must push, use the base of your palm and keep your hand open

Clamping tools Pliers

Bench vises Clamps
Bench vises:
Bench vise is a device to clamp work between their jaws.
Regular vise jaws are ser (grooved) to provide a good gripping surface.
To prevent damage of machined parts some time
protective jaw cover is used.

Use
Never use a hammer to tight or loose a vise, the
weight the body is sufficient.
of
Always use a vise big enough for the parts or type of
work to be held.
Bench vise
Clamps
Clamps are more portable and versatile than vises, but do not hold the
complete work stationary.
However, they are handy for fastening materials together, as while welding and
grinding.
Clamps are two types:
C-clamp & Parallel clamp

Pliers:
C-Clamp Parallel- Clamp
Combination Pliers:
They are used for holding work not for tightening or loosing nuts.
A slip Joint permits the jaws to be opened wider.

Diagonal Cutting Plier

end of the
They are ideal for pulling cotter pins. Also be used for spreading the
cotter pins.
Never use diagonal pliers for cutting large gauge wire

Side Cutting Pliers:

A r e used for service technician who cuts a lot oflarge gauge wire.

Mechanical Engineering Department, TICI, Polash, Narsingdi-1611

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Combination Pliers Diagonal cutting Pliers Side cutting Pliers

Nose pliers Snap ring pliers Lock grip pliers

Needle-Nose Pliers:
Are used primarily for handling small objects and for reaching into restricted
areas.

Snap Ring Pliers:

Use to spread snap rings just the right amount as they are removed or installed

Lock-Grip Pliers:
Use to clamp and hold a round object.
One Jaw is adjustable to fit different sizes of nuts, bolt heads,
pipes or rod.

B. Cutting and shaping hand tools

These tools are mainly used in cutting and shaping operation.
There are mainly 06 types of tools in this group
Sawing tools Reaming tools
Chipping tools
Filing tools
Threading tools
Punching tools

Sawing tools
Hacksaw:
Hacksaw is mainly used for cutting or spliting metallic piece into parts.
Main parts of hacksaw are frame & blade.
Frames are two types; solid and adjustable
Blade; Length- 8", 10", & 12". Width- 1/2" or 12mm Thickness-0.025"(0.6mm).

Solid frame Adjustable frame

Blade teeth are-
.14 TPI used for cutting sections of one or more inches thick.
18 TPI used for cutting section of 1/4 to 1 inch thick.( general use blade)
2 4 TPI usedfor cutting /g inch to l/4 inch thick.
32 TPI used for cutting /g inch or thinner.
Use:
Select a blade with the proper number of teeth (TPI) for the job, consider both
the kind and shape of the material to be cut.
Place blade in frame so teeth point away from handle.

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Chipping tools
Cold Chisel:
Are used for dividing and chipping.
Also used for breaking rivets and
splitting nuts.
Types of Cold Chisel
Flat chisel; for general use
Cape chisel; used for key way cutting

CAPE
Flat chisel Cape chisel
Round nose chisel; is used for cutting semi-circular grooves and chipping
inside corners, which have a fillet or radius.
Diamond point chisel; for cutting v-groove and square corners.

RUND NOSE CHE DAROND POINT CHSEL

Round nose Chisel Diamond Point Chisel

Use:
Always wear safety glasses while using a chisel.
A chisel will cut any metal softer than itself.
Always use a chisel that is big enough for the job and a hammer that is heavy
enough for the size of chisel.

Filing tools EDGE TANG

Are extensively used to
Alter tile shape of a part
Reduce the size FACE
HEEL
Remove edges
Finish surfaces that have tool marks
LENGTK-

Classification of File
SINGLE DOUBLE RASP CURVED
According to tooth cut CUT

Single cut
Double cut
Rasp cut
Curved cut
According tofineness
Smooth Smooth Second Bastord Raugh
Second cut
Cut
Bastard
Rough
According to shape orcross section
Flat file:
Half-Round file:
Round file: O

Square file
Triangular file

Use:
Before attempting to use a file equipitwith a tight fiting handle.
Normally push the file across thework.

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Punching tools ody

Shank
Handpunch
STARTING P'JNCH
Are used to make ndentations to drive pins, bolts, or
parts to align parts and also to punch holes

Classification of punch PN PUNCH

Starting punch- is used to knockout rivets and taper pin.

Pin punch - is used for driving out pins after the starting cannot longer be used.
Center Punch - is used to make the location of a hole that is to be drilled. Ine

center punch has 60° to 90° included angles.

ceT
Aligning punch is useful in shifting parts so
corresponding holes "line up". ALIGNING PUNCH

Prick punch - Prick punch is smaller than the

center punch and usually used for layout or K PU

marking purpose. The included angle of the point is 30°.

Threading tools
Hand Taps
Taps are used for cutting internal threads.
Taps are available in set, which are three in number and given the name.
Taper Plug Bottoming

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PLUG BOTTOMING
TAPER

Dies
Dies are used to cut external threads. A die of the correct size is placed in a
diestock (handle) and it is turned.
Dies are mainly two types:
Adjustable die
Solid die

Use: SsCA
U s e proper size tap drll. sCREW ADJUSTING TYPE

Lubricate tap and die during use. They should back up every one or two turns,
and keep free of chips.

Reaming tools
Hand Reamers
Reamers are multiple fluted cutting tools used for performing reaming
operation.
It produces a previously drill hole:
Perfectly round,
Smooth and a high quality surface finish
Straight and accurate dimension
Types of reamer
Taper reamer (straight or spiral)
Straight reamer (straight or spiral)
Adjustable reamer

Use:
Turn reamer in the right-hand (clockwise) direction only.
Where possible, moves the reamer completely through the work-piece while
turning. Otherwise, keep turning the reamer clockwise while pulling out side on
the tap wrench.

Mechanical Engineering Department, TICI, Polash, Narsingdi-1611