Fitting shop practice Sub Code: ES 11152

FITTING SHOP PRACTICE

Syllabus
[AS PER BASED CREDIT SYSTEM (CBCS)]
Semester – I

1. ES – 11152 WORKSHOP PRACTICE 4 Credits (0-0-8)

[Carpentry: 2 hrs, Fitting: 2hrs, Sheet metal/machine shop: 2hrs, welding: 2hrs]

OFFERED TO: First year 1ST Semester- CE, EC, EE, AE & ME
Prescribed syllabus: Introduction to safety aspects in workshop and different tools (functions, types and
Specifications) usedin different shops.

Fitting Shop: Introduction to fitting shop tools (functions, types and specifications), equipment and operations.
Fitting jobs.

Ø FITTING SHOP (2 hrs)

Introduction of shop safety, hand & measuring tools, machine tools etc 2 Hrs
Practice on filing and Hack sawing 2 Hrs
Practical job 1 : Making T Joint 10 Hrs
Practical job 2 : Making C Clamp or Making of V joint 10 Hrs
Test job / Practice Exam and Final Viva-Voce 4 Hrs
Total Hrs/Semester 28 Hrs

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7. Use first aid box or inform the faculty for need of medicalassistance.

*Strictly follow the above instructions.

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FITTING
INTRODUCTION: Machine tools are capable of producing work at a faster rate, but there are
occasions when components are processed at a bench. Sometimes it becomes necessary to
replace or repair a component that must fit accurately with one another or reassemble. This
involves a certain amount of hand fitting. The assembly machine tools, jigs, gauges etc.,
involves certain amount of bench work.
Definition of fitting shop:
“It is the process of assembling and fitting at a right place, different parts of a machine manufactured by different
manufacturing process.”
It has been divided two categories:
1. Fitting tools
2. Fitting operations
FITTING SHOP TOOLS:
These are the helping hands while fitting and assembling a machine or a part of it. They can be hand driven or
power driven. Some main fitting tools are listed below:
1. Measuring tools
2. Marking tools
3. Holding and supporting tools
4. Cutting and sawing tools
5. Striking tools
6. Drilling tools
7. Threading tools
8. Loosing and tightening tools
Measuring Tool:
These tools are used to measure the basic quantities i.e. length, mass, diameter, radius etc. They are also used
toMeasure the extent or degrees of something. some basic tools in this respect are:
1. Venire Calipers:It is used to measure and calculate the diameter (internal or external), depth, and height,
volume of sphere or cylinder. It is the most precise tool. And can calculate up to its least count. It consists of
main scale and Venire scale along with jaws for measuring internal diameter.

1. Outside jaws: used to measure external length 6. Vernier scale (cm)

2. Inside jaws: used to measure internal length 7. Vernier scale (inch)
3. Depth probe: used to measure depth 8. Retainer: used to block/release movable part
4. Main scale (cm)
5. Main scale (inch)
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2. Height Gauge:A height gauge is a measuring device used for determining the height of objects, and for marking
of items to be worked on.

3. Dial Gauge:These are top quality precision dial

gauges that combine excellent metrological
properties with extra-long life; they are smooth,
full-jewelled movement with rubies. They have
full-metal bezel and casehousing and shock proof
mechanism effective in the two directions.

0.5mm
4. Micrometers :
The word micrometer is a neoclassical
coinage from Greek micros, meaning 'small',
and metron, meaning 'measure'. The Merriam-
Webster Collegiate Dictionary[4] says that English
got it from French and that its first known
appearance in English writing was in 1670.
1. It is used to find diameter of the thin wire or very
small object.
2. It can measure length of more preciously or
correctly than venire caliper.
3. In this gauge there are two scale first scale is this A. External micrometer/Outside micrometer
horizontal scale, this is called main scale
4. The second scale is this circular scale. It has 100
divisions in one cicular
5.
Least count of Micrometer or screw gauge =
Pitch /min reading of main scale
Total No of division on circular scale
Ex: 1mm/100mm=0.01mm or 0.01/10=0.001cm

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B. Internal Micrometers : C. Depth Micrometer

D. Disc type Micrometer: For measuring of a

displacement over gear teeth, select the number of
teeth so that measuring faces may contact
tangentially with teeth surfaces at the closest
position to the pitch circle.

E. Groove type Micrometer:

To measure width of groove. To measure
width of land. To determine location of groove.
Thickness of disc : 0.75mm (.025”)

5. Steel ruler: It is a simple integrated ruler of

considerable long length. It is used to measure the
length of workpiece .but it is not the accurate or
precise way. It is used to integrate on workpiece
before cutting or adjusting the length of hole for
drilling. It is also used with callipers. It has two
types: 1.Flexible steel ruler 2.Fixed steel ruler

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6. Bore gauge:

7. Gauges Blocks: A gauge block is a block of metal

or ceramic with two opposing faces ground
precisely flat and parallel, a precise distance
apart. Standard grade blocks are made of a
hardened steel alloy, while calibration grade
blocks are often made of tungsten
carbide or chromium carbidebecause it is harder
and wears less. Gauge blocks come in sets of
blocks of various lengths, along with two wear
blocks, to allow a wide variety of standard
lengths . The process of wringing involves four
steps:[4]

1. Wiping a clean gauge block across an oiled pad

(see the accessories section).
2. Wiping any extra oil off the gauge block using a
dry pad (see the accessories section).
3. The block is then slid perpendicularly across the
other block while applying moderate pressure
until they form a cruciform.
4. Finally, the block is rotated until it is inline with
the other block.

8. Angle Protractor: A protractor is a measuring

instrument, typically made of transparent plastic
or glass, for measuring angles. Most protractors
measure angles in degrees (°). Radian-scale
protractors measure angles in radians.Some
protractors are simple half-discs. More advanced
protractors, such as the bevel protractor, have one
or two swinging arms, which can be used to help
measure the angle.

9. Bevel protractor :
A bevel protractor is a graduated circular protractor
with one pivoted arm; used for measuring or
marking off angles. Sometimes Vernier scales are
attached to give more precise readings. It has wide
application in architectural and mechanical
drawing, although its use is decreasing with the
availability of modern drawing software or CAD.
The bevel protractor is used to establish and test angles
to very close tolerances. It reads to 5 minutes or
1/12and can measure any angle from 0° to 360°.

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MARKING TOOLS:Marking refers to the process of mark something on work piece to trace back to it.
Marking out is the preliminary work of providing guide lines and centre before cutting or drilling.
Marking tools are described below:-

1. Surfaceplate:It is used for testing flatness of work

piece and for marking out small works.

2. Trysquare:It is used for marking at 90 degree. It is

also used to check whether the work piece has
cutted at right angle or not. It is made up of metal
blade fit at right angle to the straight wooden
handle.

3. Angleplate. Angle plates are used to measure and

hold various workpiece to the table during marking
operations.. .

4. Scriber.It is used to scratching a line or marking a

point on workpiece before doing any operation on it.
It is made up of hard material e.g. steel and has a
sharp, pointed edge.

5. Universal scribingblock.The scriber block may

also be used in place of a dial indicator to detect run
out (a variation in concentricity) of a workpiece
mounted in a four-jaw chuck. The scriber point acts
as a visual reference against which any variation in
the workpiece can be judged. It is also used to check
the trueness of the flat surface.

6. Odd leg caliper. It is used mainly to scribe lines

parallel to the edge of metal (or plastics) to use a
Marking Gauge.

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7. Divider: It consists of a jointed pair of legs, each

with a sharp point. They can be used for geometrical
operations such as scribing circles but also for
taking off and transferring dimensions.

8. Calipers: It measure thicknesses and diameters of

objects; inside calipers measure hole diameters and
distances between surfaces. To check the
dimensions of a machined part, the calipers are first
adjusted to the required dimension on a ruler or a
standard plug or hole gauge.

9. Punch: It is normally used to mark the centre of a

hole either by hand or on the drilling machine.
The dot punch is a lighter and thinner version of the
centre punch and is used basically for the same job.

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WORK HOLDING TOOLS:

Bench vice:-It is a work holding device, when vice handle is turned in a clockwise direction the sliding jaw
forces the work against the fixed jaw, the greater the force applied to the handle, the tighter is the work held.

V-block with clamp:-It is a rectangular (or) square block with v-groove on one or both sides, opposite to each
other. It holds cylindrical work pieces.

C-clamp:-This is used to hold work against an angle plate or v-block.

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CUTTING AND SAWING TOOLS:

Hack saw frame with blade.

The hacksaw is used for cutting metal by hand. The hacksaw blade has a number of teeth
ranging from 5 to 15 per centimeter. Lesser number of teeth is used for cutting materials like
Aluminium, brass and Bronze and large number of teeth is used for cutting hard materials like
steel, C.I etc. Hack saw blades are fitted either in a solid frame or adjustable frame to
accommodate different lengths of blade.

It is made of high-speed steel. The hacksaw blades are specified byits material, length, width,
thickness and pitch of the teeth. The common dimensions are length 250-300 mm, width 13
mm-16 mm, thickness 0.6 to 0.8 mm, pitch 1 to 1.8 mm. The blades are fixed with teeth facing
forward and the teeth are staggered, which are known as ‘set of teeth’. These make slots wider
than blade thickness, preventing the blade from jamming

Fig: Hacksaw frame with blade

Combination cutting pliers: - This is made of tool steel and is used for cutting as well as for ripping
work.
FILES:

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Types of Files:
Hand file:- It is a rectangular in section tapered in thickness but parallel in
width. Flat file:- Rectangular in section and tapered for 1/3rd length in width
and thickness. Square file:- Square in section and tapered for 1/3rd length on
all sides.
Half round file:- It has one flat face, connecting by a curved (surface) face & tapered
for 1/3rd length.
Round file:- Circular in cross section and tapered for 1/3rd length, it has double cut
teeth.

A. Flat E. Triangular I. Pillar M. Rifler

B. Hand F. Square J. Mill N. Rat fail
C. Half Round G. Warding K. Cant
D. Round H. Knife L. Barette

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STRIKING TOOLS:
Hammers:The hammer is defined as a device used to deliver blows to an object or strike another
object, in the sense that it is used for driving nails, fitting parts and breaking up objects. It is also
used for striking purposes while punching, bending, chipping, and riveting. Available in various
shapes and structures, hammers are designed for specific purpose. The hammer consists of a handle
to which a heavy head, usually made of metal is attached, with one or more striking surfaces. The
hammer is specified by its weight (125 grams to 1500 grams) and the shape of the pein.
Different types of hammers are straight pein hammer, ball pein hammer, cross –pein
hammer Material Cast steel or carbon steel.

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Fig: Types of Hammers

Ball pein hammer:-This is the most common type of hammer which has a ball-shaped end of
the head opposite to the striking face. It is used for all kinds of engineering works. The ball end
being useful for sheet metal forming and it is made in weights from 1000gm to 1.5kg. It is used
for riveting and chipping.
Cross –pin and straight pein hammer:-These have blunt, chisel-shaped ends on the head
opposite to the face. It is used for bending, stretching, hammering into shoulders, curves.

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DRILLING TOOLS:
The twist drills are used for making holes. The drills are made of HSS (high speed steel) with a
straight or taper shank. The straight shank drills are held in drill chuck and fitted to the spindle
of drilling machine and the taper shank is directly fitted to the spindle. The drills are
manufactured to standard sizes in specified steps. A bench-drilling machine is commonly used
in workshops.

THREADING TOOLS:
Taps and die holders: - Tap and wrenches are
used for cutting internal threads in a drilled hole.
Dies and die holders:- They are used for making
external threads. Dies are made either solid (or)
split type.
Spanners: - It is a tool for turning nuts and bolts. It is
usually made of forged steel

Screw driver:- It is designed to turn the screws.

The blade is made of steel and is available in
different lengths anddiameters.

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FITTING SHOP OPERATIONS:

Chipping: -Removing metal with a chisel is called chipping and is normally used where
machining is not possible.

Filing:-
1. Pinning of files:- Soft metals cause this; the pins are removed with a filecard.
2. Checking flatness and sureness
3. To check flatness across thickness of flate.

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GRINDING
Grinding is the most common form of abrasive machining. It is a material cutting process
that engages an abrasive tool whose cutting elements are grains of abrasive material known
as grit. These grits are characterized by sharp cutting points, high hot hardness, and
chemical stability and wear resistance. The grits are held together by a suitable bonding
material to give shape of an abrasivetool.

Practical applications
Surface finishing, slitting and parting, descaling, deburring, stock removal (abrasive milling)
finishing of flat as well as cylindrical surface and grinding of tools and cutters and re
sharpening of the same.

Bench Grinding Machine

A bench grinder is manually operated and normally has two wheels of different grain sizes
that are fixed on a floor stand or work bench; to perform roughing and finishing operations.
It is mainly used to shape tool bits; and repair or make various tools.

Fig: Bench Grinding Machine

Principle parts of a Bench Grinder

1. On/off switch: Starting and stopping of mainmotor.
2. Coarse grain wheel: It is generally used for roughingpurposes
3. Fine grain wheel: It is generally used for finishingpurposes.
4. Wheel guards: The operator is protected against flying abrasive particles and
ground material by the wheelguards.
5. Eye shield: Safety glass shields are provided for additional protection against glares
and flyingparticles.
6. Tool rest: A tool rest is provided for each wheel so that tools may be held or
steadied while beingground
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DRILLING
Drilling is an operation through which cylindrical holes are in a solid material by using
revolving tool.
§ Simple drillingmachine
§ Radial drillingmachine
Simple drilling machine:
This type of drilling machine is designed for drilling small holes at high speed in light work piece. It is
small machine having simple construction and operations. Fig no. shows principle parts of a sensitive
drilling machine.

Fig: Simple Drilling Machine

Radial drilling machine:This type of drilling machine is designed for drilling medium to large and
heavy work piece. Fig no. shows principle parts of a Radial drilling machine.

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1. Base: ItME
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cast iron or mildsteel.

2. Column: It is the vertical member of the machine which supports the table and
head containing all the driving mechanism. It may be of round section or boxsection.

3. Radial arm: The sleeve end arm is housed in the column. The horizontal portion
of the arm has guise ways on which the drill head and other attachments are located.
The drill head can be moved on the guide ways along its length The radial arm can
be swivelled about the column to cover a large angle. It is made ofCI.

4. Motor: Motor to lift the radial arm is located above thecolumn.

5. Elevating screw: To facilitate lifting ofarm.

6. Guide ways: As in the lathe guide way serves the purpose of movement of the drill
head long the length of thearm.

7. Drill spindle motor: A motor located on the drill head helps rotational
movements of the spindle.
Machine tool: A machine tool is a device in which energy is utilized for shaping the material into a
product by removing the excess material in the form of chips.
Machining: Machining is a process of shaping the metal product from various machine

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Experiment No.:1 FILING

Aim:-To make Rectangle of M.S Flate (45mm x 40mmx 9mm –2 Nos.) by filing.
Tools required: -
6. Hack saw withblade
1. Benchvice 7. Dot punch and Centrepunch
2. Steelrule 8. Surfaceplate
3. Trysquare 9. Venire heightgauge
4. Ball peenhammer 10.Rough and smooth flatfile
5. Scriber
Material required: - Mild steel (M.S) plate of size 48mm x 42mmx 10mm –2 Nos.
Sequence of Operations: -
1. Marking andmeasuring
2. Punching
3. Sawing
4. Filing
5. Checking flatness and squareness
6. Chipping
7. Finishing
Procedure: -
1. The burrs in the pieces are removed and the dimensions are checked with a steelrule.
2. The pieces are clamped one after the other and the outer mating edges are filed by using
rough and smoothfiles.
3. The flatness, straightness and squareness i.e. right angle between adjacent sides are
checked with help ofTry-square.
4. Chalk is then applied on the surfaces of the twopieces.
5. The given dimensions of the T-fitting are marked with help of Vernier height gauge
carefully.
6. Using the dot punch, dots are punched along the above scribedlines.
7. Using the flat file, to remove the unwanted material.
8. Using the try square check the squareness of pieces
9. The pieces (X and Y) should be rectangular and meet the given dimension.

Safety precautions: -
1. Care is taken to see that the marking dots are not crossed, which is indicated by the half
of the punch dots left on thepieces.
2. Apply pressure in forward direction during hacksawing.
3. Don’t rub steel rule on the job.
4. Fix blade in hack saw frame with correcttension.
5. During hack sawing the coolant like water or lubricating oil is to beused.
6. Use precision instruments like vernier calipers and vernier height gaugecarefully.
7. Files are to be cleaned properly after using.

Result: - T-fit is made as per the required dimensions.

Conclusion: The model prepared is within / beyond the tolerance.

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Experiment No.:1 T FITTING

Aim:- To make M.S Plate into required model by T-fitting.

To make a T-fitting from the given two M.Spieces.
Tools required: -
6. Hack saw withblade
1. Benchvice 7. Dot punch and Centre punch
2. Steelrule 8. Surfaceplate
3. Trysquare 9. Venire heightgauge
4. Ball peenhammer 10. Rough and smooth flatfile
5. Scriber 11. Flat chisel and triangularfile

Material required: - M.S Flate (45mm x 40mmx 9mm –2 Nos.)

Sequence of Operations: -
1. Filing
2. Checking flatness and squareness
3. Marking andmeasuring
4. Punching
5. Sawing
6. Chipping
7. Finishing
Procedure: -
1. The burrs in the pieces are removed and the dimensions are checked with a steelrule.
2. The pieces are clamped one after the other and the outer mating edges are filed by
using rough and smoothfiles.
3. The flatness, straightness and square ness i.e. right angle between adjacent sides are
checked with help ofTry-square.
4. Chalk is then applied on the surfaces of the twopieces.
5. The given dimensions of the T-fitting are marked with help of Vernier height gauge
carefully.
6. Using the dot punch, dots are punched along the above scribedlines.
7. Using the hack saw, the unwanted portions areremoved. Fig x
8. Using drill machine, remove the material at B side. Fig y
9. Using the flat chisel, the unwanted material in the piece Y isremoved.
10. The cut edges are filed by the rough and half roundfile.
11. The corners of the stepped surfaces are filed by using a square or triangular file to get
the sharpcorners.
12. The pieces (X and Y) are fitted together and the mating is checked for the correctness
of thefit.

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x Y

Safety precautions: -

1. Care is taken to see that the marking dots are not crossed, which is indicated by the half
of the punch dots left on thepieces.
2. Apply pressure in forward direction during hacksawing.
3. Don’t rub steel rule on the job.
4. Fix blade in hack saw frame with correcttension.
5. During hack sawing the coolant like water or lubricating oil is to beused.
6. Use precision instruments like vernier calipers and vernier height gaugecarefully.
7. Files are to be cleaned properly after using.

Result: - T-fit is made as per the required dimensions.

Conclusion: The model prepared is within / beyond the tolerance.

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ExperimentNo:2 V -FITTING

Aim: To make M.S Plate into required shape by V- fitting.

To make a V- fitting from the given two M.S pieces.

Tools required: -
6. Hack saw withblade
1. Benchvice 7. Dot punch and Centre punch
2. Steelrule 8. Surfaceplate
3. Trysquare 9. Venire heightgauge
4. Ball peenhammer 10. Rough and smooth flatfile
5. Scriber 11. Flat chisel and triangularfile

Material required: - Mild steel (M.S) flate of size (45mm x 40mmx 9mm –2 Nos.)

Sequence of Operations: -

1. Filing 5. Sawing
2. Checking flatness and squareness 6. Chipping
3. Marking andmeasuring 7. Finishing
4. Punching

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Procedure: -
1. The burrs in the pieces are removed and the dimensions are checked with a steelrule.
2. The pieces are clamped one after the other and the outer mating edges are filed by
using rough and smooth files.
3. The flatness, straightness and square ness i.e. right angle between adjacent sides are
checked with help of Try-square.
4. Chalk is then applied on the surfaces of the two pieces.
5. The given dimensions of the T-fitting are marked with help of Vernier height gauge
carefully.
6. Using the dot punch, dots are punched along the above scribed lines.
7. Using the hack saw, the unwanted portions are removed. Fig x & Fig Y
8. Using the triangular file, corners of the stepped surfaces are filed to get the sharp
corners.
9. The pieces (X and Y) are fitted together and the mating is checked for the correctness
of the fit.
Safety precautions: -

8. Care is taken to see that the marking dots are not crossed, which is indicated by the half
of the punch dots left on the pieces.
9. Apply pressure in forward direction during hacksawing.
10. Don’t rub steel rule on the job.
11. Fix blade in hack saw frame with correct tension.
12. During hack sawing the coolant like water or lubricating oil is to because.
13. Use precision instruments like vernier calipers and vernier height gauge carefully.
14. Files are to be cleaned properly after using.

Result: - T-fit is made as per the required dimensions.

Conclusion: The model prepared is within / beyond the tolerance

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