SECTION

SAFETY PRECAUTIONS
1. Do not use a file without a handle.
2. Do not use punches and hammer with mushroom head.
3. Do not use hammer with a loose head.
4. Keep your hands away from moving parts.
5. Ensure that the work piece is clamped in the vice firmly and securely.
6. Keep the hand tools and vice clean
7. Always use a brush to remove any chips.
8. Always roll up your sleeves (or) wear short sleeves.
9. Tuck in your shirts before starting any operation.
10. Remove wristwatches, rings, bracelets, bangles etc., since they can lead to injuries.
11. Wear always safety shoes.

DEFINITION

Fitting is working a part to make it fit its mating part in a joint. This mating part
should be completely finished.

SCOPE OF FITTING JOBS

Today, mechanical engineering cannot do anything without fitting operation. Any
machine, mechanism of instrument requires the fitter for its assembly and adjustment. Fitting
practice covers a great range of jobs including assembling, repairing, tool making and
instrument setting, etc. Despite the various specialties, all fitters must be proficient in such
typical metal working operations such as laying out, clipping, straightening, bending, cutting,
filing, drilling, contour sinking, counter boring, reaming, threading, riveting, fitting, lapping,
soldering, tinning and adhesive bonding.

TOOLS USED IN FITTING SHOP AND HANDLING OF THE TOOLS

1. Marking and Measuring Tools 2. Holding Devices 3. Striking Tools,
4. Cutting Tools / Chipping Tools 5. Finishing Tools

MARKING AND MEASURING TOOLS

These tools are generally used for setting or marking out and checking the work at
various stages. Common tools used for the marking purposes are
1. Steel rule 2. Caliper 3. Divider and Trammel 4. Punch 5. Try-
square 6. Scriber
7. Protractor 8. Surface plate 9. Surface gauge 10. Vernier height gauge
11. Angle plate 12. Marking hammer

STEEL RULE
It is the tool used for taking linear measurements to the nearest 0.5mm. For layout
work in engineering, the commonly used unit of measurement is millimeter, which is 1/1000
part of a meter. Steel rules are available in different length. Steel rules of 600, 300 and
150mm lengths are most commonly used.
These steel rules are made from spring steel (or) stainless steel strip.

1
CALIPER
Inside caliper
It is a two-legged instrument with its legs bent outwards. By adjusting the screw, the
movement of legs is controlled. It is used to measure internal diameters, width of slots,
keyways, channels and other inner measurements of pipes, holes, bores, grooves, measuring
gaps etc.

Fig 1.1. Steel rule A – Rigid: B – Flexible

Outside caliper
It is a two-legged instrument with its legs bent inwards. By adjusting the screw, the
movement of legs is controlled. Outside calipers are used to measure outside
dimensions of round bars, flats, grooves, and steps for measuring and comparing
thickness. This is a very ideal tool for measuring diameter.

Fig 1.2 (a) Inside Caliper Fig 1.2 (b) Outside Caliper Fig 1.2 (c) Jenny Caliper

Jenny caliper
The Jenny caliper has one leg bent inside and the other leg straight. The caliper is
used for marking parallel lines and for finding out the center of the round bars. For marking
parallel lines, the bent leg is moved along the straight edge of the job and as the caliper is
moved, the line parallel to the edge is drawn with the straight leg. This caliper is also named
as Morphy caliper and Hermophrodite.

All the above calipers are coupled with quick acting spring and knurled solid nut to set
the dimensions by means of releasing the nut on a finely threaded adjusting screw. By
2
adjusting the screw the movements of the legs are controlled. The size of the caliper is
determined according to the length of the leg. This is made from hardened steel.

Fig 1.3 (a) Divider Fig 1.3 (b) Trammel

DIVIDERS
It is a very useful tool in layout work. They are used to mark out circles, arcs,
perpendicular lines, bisecting lines and curvilinear lines and for plotting geometrical figures.
They are also used to transfer dimensions from steel rule to work pieces. It is made from
hardened steel, which keeps the points always sharp. It has two legs, which are firmly fixed
by means of screw at the joints. Other type has a spring joint where legs are held by a spring.
The length of leg determines the size. For longer sizes, the use of Trammel [fig.1.3(b)] is
preferred as exact adjustments are difficult with dividers because of wide angle between the
legs. Trammel is a tool used for laying large circles, arcs, radius, bisecting a line, marking a
line etc., This tool is especially used for laying out material for boilers, tanks, bridges, towers
etc. It consists of one solid beam and different types of legs, which can be slid and fixed at
any place on the beam for doing a variety of markings.

SURFACE PLATES
Jobs are mounted on the surface plate for marking and measuring precision jobs,
specially pre-machined jobs. The surface plate and marking plate have similar shapes. The
difference lies in the accuracy of flat surface. The surface plates are more precision than
marking plates. Also to maintain the accuracy of surface plates for long time, small surface
plates are made of different materials such as hardened steel and granite stone, apart from
very well seasoned cast iron. The cast iron plates are cheap because they are easily cast and
machined.

3
Fig 1.4 Surface Plate

Fig 1.5 Surface gauge

SURFACE GAUGE

This is the main tool for three-dimensional layout. This is used along with the marking plate
to scribe vertical, horizontal and parallel lines, to locate the centre of round bar, for setting of
jobs on the tables for machining, checking of height and position of work pieces setup on
surface plates

TRY SQUARE
It is a fine precision tool having true right angular edges. This tool is usually employed
to check the flatness of a surface or squareness of adjacent edges. It is also often used for
marking parallel lines, setting jobs etc. It consists of a Blade and Stock. The blade and stock
may be, riveted together (or) detachable, or one solid integral part.

Fig 1.6 Try Square and its use

4
The Try squares are available in a wide range of sizes. Fig.1.6 shows the usage of Try square.

5
SCRIBER
Scribers look like pencil of 3 or 4 mm diameter and 200 mm long. These scribers are
used for marking lines on work surfaces with reference to edge of any tool template, steel
rules or squares. One end of the scriber is pointed to 15 0 and other end is bent. Scribers come
in three main varieties such as single point, double point and removable point types.

Fig 1.7 Scriber Fig 1.8 Punches Fig 1.9 Protractor

PUNCHES
These are sharply pointed tools used for marking indentations on the scribed lines in
order to make them more clearly visible. Punches are made from tool steels (or) hardened
steels. These punches are classified as Center punch and Dot punch. Both punches look the
same except that they differ in their point angles. The dot
punch point angle is generally between 30o and 60o but when ground to 30 o, it is called as
Prick punch. The dot punch is used to make small punch marks on layouts, lines to make them
last longer. The centre punch is ground to 90o to make the mouth of the punch mark wide
enough to receive the drill point comfortably. Centre punch is used to widen the mark made
by the dot punch.

PROTRACTOR
The Protractor shown in fig. 1.9 has a rectangular protractor head providing all four
sides as working edges. The flat big surface on the back helps laying out the tool flat up on
the paper or the work. The thumbnut locks the blade in the required position. The graduated
blade is available to measure the depth of hole, groove and cavity.

VERNIER HEIGHT GAUGE

This gauge is designed to scribe vertical distances from plane surface like the ordinary
height gauge. It is intended for accurate layout work. It consists of a base to which a
graduated vertical beam is rigidly secured, a slide with Vernier and lock screw, a fine
adjustment device, a scriber offset, and a scriber. The scriber is held with a holder on the jaw.
The scriber can be sharpened several times and when worn out can be replaced.

6
Fig 1.10. Angle Plate Fig 1.11. Bench Vice Fig 1.12 Hand Vice

HOLDING DEVICES
ANGLE PLATE
The angle plate has two plain surfaces at right angles to each other. The sides are
machined at 90o. Holes, slots that enable to hold the work are made through the surfaces. It is
made of cast iron. Angle plates are used to hold parts on either the vertical or horizontal
surfaces.

VICES
These are the work-holding fixtures for clamping the work in the required position.
Different types of vices are used in practice such as Leg vices, Parallel bench vices and Hand
vices. Leg vices, which are simple and very strong, are used occasionally for crude and heavy
jobs that involve chipping, riveting, bending, etc. Hand vice is used to grip small work pieces
for drilling (or) filing when they are inconvenient/hazardous to hold by hand.

Hand operated plain parallel bench vices are most commonly used work-holding
device for clamping work in the required position. This is mounted on a bench or on a
machine bed. Bench vice is fixed to the bench with nut and bolt. The vice body consists of
two main parts, fixed jaw and movable jaw, made of cast iron. The vice movement is caused
by the movement of the screw through the nut fixed under movable jaw. This screw is
provided with a collar inside to prevent it from coming out of the jaw, when rotated. Fig. 1.11
and 1.12 exhibits the details of a Bench vice and Hand vice.

STRIKING TOOLS
HAMMERS
Hammers are believed to be man’s primitive tool. Hammers are made from structural
and tool steels; the head is hardened and tempered. An eye is provided in the middle of the
hammer for a handle. Hammers are available in many sizes and weighs from 100gm to 10kg
and with many shapes of head.

Ball peen hammer

This is the most common type of hammer, which has a head with one end as ball shaped and
the other end flat, This flat end is the striking face. It is used for all kinds of engineering
work. The ball portion is used to straighten, soften and expand metal into the desired shape.
Cross peen hammer

7
 These have blunt chisel shaped ends on the head opposite to the face. This is used for
chipping, riveting and sheet metal shapes for bending, providing channels and collars,
swaging etc.

Straight peen hammer

The Peen of this hammer is flat but straight to the handle. This is commonly used for
bending channels, working on corners, etc.,

Fig 1.13. Ball and Cross peen hammers Fig 1.14. Straight peen hammer

CUTTING TOOLS/CHIPPING TOOLS

These tools are used for chipping, chiseling, sawing and scraping. Chisel is the
simplest form of metal cutting tool in which the wedge shape is the most pronounced. Chisels
used in the fitting shop for chipping and chiseling are called “COLD CHIESELS”. They are
made of cast steels (or) carbon tool steel and the cutting edge is hardened and tempered. They
are classified according to their shape and cutting edge width.

Flat Chisel
The common form of chisel is flat or cold chisel. It is so called because it is used to
cut cold metal. In this type, the cutting edge is convex to avoid the damage to the corners
while in use. This radius reduces the possibility of the corners breaking off. The cutting edge
is ground to an angle of approximately 60 o and the edge width varies from 20 to 30mm. Only
the cutting edge is hardened or tempered. The head of the chisel is left soft so that hammer
faces are not
damaged.

8
Fig 1.15. Types of Chisels Fig 1.16. Hacksaw Frame with blade

9
Half-Round Chisel
A half round chisel is particularly useful for cutting oil ways, grooves in bearings,
bosses and pulleys, forming flutes, bringing drill holes in the correct position when set out
inaccurately. They are also used for setting over pilot holes. The shank is reduced to a half
round taper, which is beveled at the end to give a circular edge

Diamond-Point Chisel
This type of chisel has cutting edge like a Diamond-point. It is used for cutting Vee-
grooves, marking sharp corners, cleaning corners and squaring small holes. The chisel is
drawn to a square section.

HACK SAW
Hack sawing is a process of removing small chips of materials by series of small teeth.
The hacksaw is a tool designed for cutting thick metal sheets, round bar of bar stock of round
and other sections and also to cut slots, contours etc. This is also used to draw vertical,
horizontal and parallel lines.

Fig 1.17. Typical View of the blade Fig 1.18. Mounting a hacksaw blade

A hand hacksaw has a frame and blade. At one end of the frame there is a fixed holder
with handle and pin holders and at the other end, an adjustable holder with a blade tightening
screw and wing nut. Both the holders have slits to accommodate the cutting blade secured in
the pins. Hacksaw frames are made either fixed for a blade of a given length or adjustable,
which allow blades of different length to be used.
Hack saw blades are commonly available with the following grades. Coarse: 14 teeth
per 25mm (14TPI) for thick and soft metal
Medium: 22 teeth per 25 mm (22 TPI) for medium work: Fine: 32 teeth per 25 mm (32 TPI)
for hard metal. The details of blade are given in the figure 1.17.
The blade is so placed into the holders that the teeth point away from the handle and
not the other way round. One end of the blade is first inserted into the fixed holder and locked
with a pin, and then the other end is inserted into the opposite holder and likewise fixed there.
The correct and incorrect way of mounting the blade on the frame is shown in figure1.18.

FINISHING TOOLS
Files
Filing is a cutting operation on metals or other materials, which involves the removal
of stock in small quantities by hand or by machines using a file. The file is a basic tool for

10
giving the work the necessary shape and size, for fitting it to another part, for preparing its
edges for welding, and for a variety of other manufacturing applications.
Files are used for working flat and curved surfaces, slots, grooves, holes of various
shapes, angular surfaces, etc. Filing allowances are usually small, from 0.025 mm to 0.5 mm.
Accuracies that can be achieved by filing range from 0.2 to 0.05 mm, and , in special cases,
even to 0.001 mm.

Parts of a file
File is essentially a steel rod of a certain shape and length which has wedge-like teeth
cut on its surfaces. Files are made from tool steels (or sometimes from chromium steels) and
heat treated after teeth cutting.
A file consists of the following parts:
FACE: The surface of the file where teeth are cut is called the face. A file may have
one or more than one face. A flat file has two faces.
EDGE: The side of the face is called the edge. If teeth are not cut on it, it is called a safe edge
file, e.g. a hand or mill file. The edge is kept safe so that it does not cut the side of the job
while filing. However, the teeth on the teething edge are always single-cut.
BELLY: Some files have one-third of their length tapered in width, and thickness. The
tapered portion is called the belly.
TIP : The opposite side of the tang is called the tip which is near the belly. The stroke is
always taken towards the tip in machinist files. It is also known as POINT.
HEEL: The uncut portion on the face near the shoulders is called the heel. Generally the
grade and the manufacturer’s name are stamped at this place.
SHOULDER: The tapered portion at the end of the edge and near the tang is called the
shoulder.
TANG: The extreme narrow part opposite the point is named the tang. This portion is kept
safe because it is thinner and the handle is fitted over here.

Classification Of Files

Files are manufactured in a variety of

types and shapes, each for a specific
purpose. They may be divided into Two
classes namely Single cut and Double cut
as shown in fig. 1.20(a).

Single cut files have single row of parallel

teeth running diagonally across the face.
They include mill, long-angle lathe and
saw files. Single cut files are used when
smooth finish is desired (or) when hard
Fig. 1.19 Parts of File materials are to be finished. These files
are used for metals like brass, Babbitt,
lead, aluminium, bronze and copper with
low resistance to cutting and also for
non-metals. These types of files are also
employed for sharpening saws, knives
and for working in wood and cork.

Double cut files have two intersecting rows of teeth. The first row is usually coarser
and is called as the overcut. The other row is called as the upcut. These intersecting rows

11
produces hundreds of cutting teeth which provide fast removal of metal and easy cleaning of
chips. Both single and double cut files manufactured in various degrees of coarseness such as
rough, bastard, second cut, smooth and dead smooth as shown in figure 1.20(b). The files
most commonly used by the machinists are bastard, second cut and smooth files. By
application files are classified into the following groups: general-purpose files, special-
purpose files, needle files, and rasp files. Based on the cross section the general purpose files are
further classified as hand, flat, square, triangular, round, half round, lozenge and knife edge as shown in
figure 1.20(c) .

1.20(a) Single and 1.20(b) Classification on the 1.20(c) Classification on the

Double cut Files Basis of Coarseness Basis of Cross Section

A- hand and B – flat files are used for filing flat outside and inside surfaces, grooves and
slots.
C - Square files are used for filing out square, rectangular, and polygonal holes, for filing
narrow lands.

D – Triangular files are used for filing corners to angles of 600 and over in grooves, slots,
holes, and for sharpening wood saws.

E – Round files used for filing out round, elliptical and curved openings, and concave
surfaces with small radius.

F – Half round files used for concave surfaces with considerable radii and large holes (filing
with the convex face) and for flats, convex surfaces and corners with angles of 300 and over
(filing with the flat face);

G – lozenge files used for filing teeth in discs, gears, and sprockets, for deburring machined
teeth in such parts, for filing slots and corners to angles of 150 and over;

H – knife files used for filing corners, grooves, narrow slots, and flat sides in triangular,
square, and rectangular openings in various machine parts, and also in cutting tools, dies.
Files of all these types excluding round ones are produced with chisel – cut and milled teeth.

12
 1.21 Needle Files 1.22(a) Diamond Files 1.22(b) Rasp Files

Other grades are used for special jobs only. Special files are intended for specific applications,
e.g. for filing non-ferrous alloys and non-metals, and for hardness testing.
Hardness – testing files are used where hardness cannot be checked by standard methods, i.e.
at such hard-to-reach places as gear-tooth flanks, milling cutter blades, etc., or for checking
hardness on the shop floor at heat-treatment installations. Such files are ‘Calibrated’ for
specific hardness depending on the hardness of the work.
Needle files are small files as shown in figure 1.21 and used in tool and jewelry making,
engraving, and finishing in various places, which are difficult to get at (holes, corners, lands,
etc.)
Diamond files are employed in tool making for working and finishing cemented – carbide
components of cutting tools and dies. A diamond file is basically a metal rod of the specified
section whose face is covered with a thin diamond layer. The diamond-powder grain size
varies according to application. [Fig.1.22]
Rasp files are employed for filing soft metals (lead, tin, copper, etc) and non-metals (leather,
rubber, wood, plastics), when standard files rapidly clog and stop cutting. [Fig.1.22]

Methods of filing
There are four methods of filing a surface using a hand file.

Cross filing
This method is preferred for maximum removal of metal in minimum time. The
strokes of file are run alternatively from right to left and then left to right. The idea of
changing the direction from time to time is to keep the area of contact as large as possible
during filing for maximum metal removal. The possibility of the surface becoming curved is
quite small due to continuous changing of directions.

Straight filing
In this method, the file is pushed forward at right angles to the length of work and
lifted clear off the work during the backward stroke. It is best suited for long and narrow jobs
having lesser width

13
Diagonal Filing
To obtain a true and smooth surface the direction of file movement must be varied
which is possible by diagonal filing. In this, first the file direction is from left to right at 30 0 to
the vice axis and vice versa. Such sequence provides the required flatness and surface finish.

Draw filing
It is a simple method of filing to produce good finish on the edge of long and narrow
work pieces. The file is held in both the hands across its body as close as possible. The file is
placed at right angles to the work and pushed backward and forward, along the edge being
filed. A fine cut file with a flat face should be used for draw filing.

DRILLING
Drilling is a process of making holes in a solid material using DRILL. The machines
intended for drilling is termed as Drilling machine. Drilling is applied for holes of low grade
accuracy and surface finish.
Step Cone Pulley
V-Belt

Drill
Feed
Handle

Motor
Column Spindle

Drill

Table

Table
Clamp
Fig.1.23 Sensitive Drilling Machine
Base

Holes are drilled for fastening parts with rivets, bolts or for producing internal threads.
Sensitive drilling machine is the most versatile machine used in a fitting shop for this purpose.
Twist drills are made of tool steel or high-speed steel are used with the drilling machine for
drilling holes. Following are the stages in drilling work.
1. Select the correct size drill, put it into the chuck and lock it firmly
2. Adjust the speed of the machine to suit the work by changing the belt on the pulleys.
Use high speed for small drills and soft materials and low speed for large diameter
drills and hard materials.
3. Layout the location of the hold and mark it with a centre punch.
4. Hold the work firmly in the vice on the machine table and clamp it directly onto the
machine table.
5. Put-on the power, locate the punch mark and apply slight pressure with the feed
handle.
6. Once drilling is commenced at the correct location, apply enough pressure and
continue drilling. When drilling steel, apply cutting oil at the drilling point.

14
 7. Release the pressure slightly, when the drill point pierces the lower surface of the
metal. This prevents the drill catching and damaging the work or drill.
8. On completion of the drilling, retrace the drill out of the work and put-off the power
supply.

Twist drill
The tool used for drilling is termed as drill. Twist drill is most commonly used tool for
making holes. It is typically a two flute-cutting tool having two main parts namely the Body
and the Shank. are used for making holes. These are made of high-speed steel. Both straight
and taper shank twist drills are used.
Body Flute Web
Shank Margin Point Body Lip
clearance

Margin
Cutting Edge

Heal
Chisel edge
Fig.1.24 Nomenclature of twist drill

Designation of twist drills

Millimeters from 0.4mm onwards; Inches from 1/64” onwards; Letters drills A to Z
Number drills 60 to 20: Taper shank drills 3 to 100mm

THREAD CUTTING TOOLS

Screw threads are produced by thread cutting, drilling, turning and by rolling. Threads may
also be cut manually using Taps and Dies.

TAPS AND TAP WRENCHES

A tap is a hardened steel tool, used for cutting internal threads in a drilled hold. Hand taps are
usually supplied in sets of three for each diameter and thread size. Each set consists of a taper
tap, intermediate tap and plug or bottoming tap.[figure1.25] In hand tapping, taps are driven
with the aid of wrenches set on the blank square. The details of a bar type tap wrench is
illustrated in figure1.26.

15
 Fig.1.25 Set of tap

Fig. 1.26 Bar type tap wrenches Fig. 1.27 Method of Tapping

The following are the stages involved in tapping operation.

1. Select the correct size tap, with the desired pitch.
2. Select the correct size tap drill, usually indicated on the tap.
3. Drill the hole.
4. Secure the tap in the tap wrench.
5. Insert the first or taper tap in the hole and start turning clockwise, by applying downward
pressure.
6. Check the alignment of the tap with a try square and correct it if necessary, by applying
sidewise pressure, while turning the tap.
7. Apply lubricant while taping in steel.
8. Turn the tap forward about half a turn and then back until chips break loose. Repeat the
process until threading is completed with intermediate and bottoming taps.
9. Remove the tap carefully. If it gets stuck, work it back and forth gently to loosen.
A bar type tapping is illustrated in figure1.27.
Note:
1. It is a good practice to drill a small countersink, about the depth of a one thread to ensure
that a burr is not thrown up when tapping the hole.
2. While tapping in blind hole, remove the tap and clear the chips often so that the tap can
reach the bottom of the hole.

16
 CUTTING EXTERNAL THREADS
External threads are cut with round threading dies. These dies are of two types namely
solid and split types as described in figure 1.29.

DIES AND DIE-HOLDERS

Fig. 1.28 Round threading dies Fig. 1.29 Thread cutting with round threading die

Dies are the cutting tools used for making external threads. Dies are made either solid
or split type. They are fixed in a die-holder for holding and adjusting the die gap. They are
made of tool steel or high carbon steel. Cutting with a threading dies is illustrated in figure
1.30.
The following are the stages in producing external threads:

1. Prepare the work with a chamfer at its end.

2. Select the correct size die.
3. Position the die in the die-holder. Tighten the set-screws so that the dies is held firmly in
its place. Incase of adjustable die, set the die to cut oversize threads first.
4. Fasten the work firmly in a vice.
5. Place the die over the chamfered end of the work and start cutting threads by turning it
clockwise while applying downward pressure. Apply cutting fluid while threading in
steel.
6. Turn back the die for the chips to break loose. Continue until threading is completed.
Check the threaded work to see if it fits the tapped hold or nut. If the fit is too tight, adjust
the die for a slight deeper cut and complete the threading again.

17
Section PLUMBING
SAFETY PRECAUTIONS IN PLUMBING SHOP
1. Wear shoes while working in the shop
2. Use right tool for the job
3. Keep cutting and measuring tools separately
4. Do not walk on the wet floor

DEFINITION

Plumbing is a utility consisting of the pipes and fixtures for the distribution of water or gas in
a building and for the disposal of sewage. Plumbing refers to installation of pipelines, water
tanks and other pipe fittings to distribute water in a building. The plumbing water supply
system comprises of pipes, valves, storage tanks etc. and plumbing drainage system consists
of wash basins, water closets, urinals, septic tanks etc.

PLUMBING TOOLS

PVC (Poly Vinyl Chloride) pipes and GI(Galvanized Iron) pipes are commonly used
in plumbing. The following tools are used to install fittings in plumbing.

Pipe wrench:
Pipe wrench is used to hold and tight soft iron pipes and fittings with round surface.
the pipes. It consists of fixed jaw and movable jaw with adjusting screw. The design of the
adjustable jaw allows it to rock in the frame, such that any forward pressure on the handle
tends to pull the jaws tighter together.

Fig 6.1 Pipe wrench

Pipe vice:
Pipe vice is a clamp for holding pipe that is to be cut or threaded. It consists of fixed
jaw, movable jaw with adjusting screw.

18
 Fig 6. Pipe vice

Pipe fittings:
PVC pipe connection uses fittings like elbow, bend, coupling, tee reducer, whereas GI
pipe connections use fittings like elbow, bend, coupling, tee reducer with V-thread.

Fig 6.3 a) Bend b) Elbow c)Tee joint

Fig 6.4 a) Plug b) Flange c)Coupling

19
Bend:
It is used at corners to connect two pipe lines. Bends are joined by joined to the pipe
by coupler. The advantage of bend is that the water pressure is not dropped.

Elbow:
In appearance it looks like elbow of human. It is used for connecting two pipes at right
angles. The elbow’s outside diameter is similar to the coupler.

Tee joint:
T joint is used to connect branch line from main pipe line.

Coupling:

Couplings are used to join two pipes in a straight direction.

For domestic water supply valves and taps are used to control the flow of water.
Globe valve is used in pipe lines for convenience in manually closing the pipes to
control the flow of water. This valve has quicker opening and closing. Pillar taps are draw-off
taps that are fitted to sanitary appliances such as sinks, wash basins. They have long threaded
shank, that allows the to be fitted into the appliance.

Fig 6.6 Pillar tap

Fig 6.5 Globe valve

20
21
22
23
 STEP FITTING

AIM:
To construct Step fitting using mild steel work piece.

SUPPLIED MATERIAL SPECIFICATION:

Mild steel metal plates of dimension is (50 x 50 x 6) mm

TOOLS REQUIRED:
1) Hack saw frame with blade. 2) Try square. 3) Steel rule. 4) Jenny caliper 5) Files.

6) Ball peen hammer. 7) Centre punch. 8) Dot punch

SEQUENCE OF OPERATION:
1) Preparation. ) Marking. 3) Cutting. 4) Filing. 5) Finishing. 6) Fitting

WORKING STEPS:

1) PREPARATION
1. Check the initial dimensions using steel rule.
2. Fix the job on a bench vice and file and two adjacent sides using a flat file to
form right angles.
3. Check for the perpendicularity with try square.
2) MARKING:
a) Apply chalk on the work surface.
b) Measure the given dimension using jenny caliper from the steel rule.
c) Transfer the measured dimensions to the work piece
d) Mark the dimensions on the work piece with one of the filed sides as reference
edge.
e) Repeat the above steps with the next edge as reference edge to mark the
dimension.
f) Scribe lines along the marked dimensions on the work piece.
g) Make dots along these lines using dot punch which is called as PUNCH
LINES.
h) Draw lines parallel to these punch lines at a distance of 2mm from them, which
are called CUTTING LINES..
3) CUTTING:
a) Fix the work piece in the bench vice in such a way that the cutting line is
perpendicular to the jaws of the vice.
b) Cut along the cutting lines.
c) Repeat the steps till cutting id finished along all the cutting lines by rearranging
the work piece in the vice..
d) Must ensure that cutting is carried out along all the cutting lines.

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 4) FILING:
a. Fix the work piece in the bench vice in such a way that the cutting edges
(punch lines) are parallel to the jaws.
b. File the cut edges using flat rough file to a distance of 2mm, so that the punch
lines are exposed.
c. Remove and refit the work piece in the bench vice to make the next set of cut
edges parallel to the jaws.
d. File the cut edges using flat rough file to a distance of 2mm
e. Must ensure that filing is carried out along all the cutting edge punch lines.

5) FINISHING:
a) Using a flat smooth file to produce a smooth surface finish in all the filed
edges.

6) FITTING:

Check for true form with a mating gage and for symmetry about the axis with a
Verniercaliper. The fitting accuracy is considered if both contours mate without
misalignment and clearances.

RESULT:
Thus a Step Fitting is obtained out of the given work piece with specified
dimensions, shape, finish and accuracy with proper fitting,

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 DRILLING AND TAPPING
AIM:
To make drill and tap on given mild steel work piece.

SUPPLIED MATERIAL SPECIFICATION:

Mild steel metal plates of dimension is (50 x 50 x 6) mm

TOOLS REQUIRED:

1) Hack saw frame with blade. 2) Try square. 3) Steel rule. 4) Jenny caliper 5)
Files.

2) Drilling M/c. 7) Tapping M/c. 8) Dot punch. 9) Thread pitch gauge

SEQUENCE OF OPERATION:

1) Preparation. ) Marking. 3) Drilling. 4) Tapping. 5) Finishing.

WORKING STEPS:

1) PREPARATION

4. Check the initial dimensions using steel rule.

5. Fix the job on a bench vice and file and two adjacent sides using a flat file to
form right angles.
6. Check for the perpendicularity with try square.

2) MARKING:

i) Apply chalk on the work surface.

j) Measure 20mm using jenny caliper from the steel rule.
k) Transfer the measured dimensions to the work piece with edge 12mm.
l) Draw lines along the dimensions on work piece with scriber.
m) Make dots along these lines using dot punch..

3) DRILLING:

e) Place the work piece on the drilling machine platform..

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f) Using drilling machine make two holes on the dotted place made by dot
punch.
g) Pour some oil for smooth drill and drill the work piece properly by adjusting the
pilot.
h) Repeat the steps twice for better finishing..
i) Lastly go to the thread pitch gauge machine & complete the drilling
procedure on the work piece.

4) TAPPING:
f. Fix the work piece in the bench vice in such a way that it should not move.
g. Using Tapping tool 1 make threads in the holes..
h. Repeat the procedure for both .holes, then take the taping tool 2 and use it
carefully by rotating in clockwise, simultaneously do this process for both
holes. .
5)
6)
7)
8)
9)
10)
11) FINISHING:
b) Using a 10mm screw, check the accuracy of the finish.

RESULT: The required holes using Drilling & Taping techniques with proper
measurements has been obtained,

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 STEP TURNING
AIM:
The aim of this exercise is to turn a given work piece to the required dimension..
SUPPLIED MATERIAL SPECIFICATION:
Mild steel rod 12 mm diameters
TOOLS REQUIRED:
2) Chuck key 2) Turning tool 3) Tool post key 4) Vernier caliper

5) 5/16 Spanner.
OPERATION:
Step turning is an operation performed on lathe to produce a cylindrical job of
different diameters.
PROCEDURE:
7. Chuck the work piece as per the procedure and mount the turning tool on the
tool post
8. Face the both ends of the work piece and ensure that ends are perpendicular
to the axis of the work piece after facing..
9. Now set the turning tool perpendicular to the lathe axis.
10. Set the tool to touch the work piece. Measure the diameter of the work piece
and set the reading in the reading collor to zero. This reading is the reference
point. Subtract the required diameter from the measured diameter. Half of this
is the required depth of cut.
11. Start the lathe; divide the depth of cut in steps of 0.5mm.
12. Give roughing cut in steps over a length of 7mm until the diameter is slightly
more than 8mm.
13. Finish turn to 70mm over a length of 75mm.
14. Turn the work piece to slightly more than 10mm diameter over a length of
50mm from free end. The reduction in diameter can be done in a number of
steps as done previously.
15. Replace the roughing tool with a finish turning tool.

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16. Finish turn for 8mm diameter.
17. Check the accuracy of the turned diameters.
18. Chamfer the work piece for the specified dimensions on both ends

RESULT:
The given job is TURNED to the required dimensions and finish..

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 PLUMBING
AIM:
Using the given components completely join the pieces to make the arrangement as
shown in figure.
APPLICATION:
Used for house hold purpose..
SUPPLIED MATERIAL :
1) 1” x 6” GI pipe 2) 3/4” x 6” GI pipe 3) 1/2” x 6” GI pipe 4) 1/2” x 3” GI pipe

5) 1/2” PVC pipe tap 6) 1/2” Dummy 7) 3/4” x 1/2” reducer 8) Ball valve
9) 1/2” Steel plug 10) 1/2” Coupling
TOOLS REQUIRED:
3) Adjustable spanner. 2) Pipe Wrench. 3) Pipe Vice. 4) Double end Spanner

5) Ring Spanner.
SEQUENCE OF OPERATION:
2) Setting. 2) Joining. 3) Tightening. 4) Checking

WORKING STEPS:

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 7) SETTING:
19. Set the given materials as required in the figure

8) JOINING:
n) The given materials are joined as required in the figure

9) TIGHTENING:
j) The joints are tightened by using pipe wrench or Adjustable spanner or Double
end spanner or all

10)CHECKING:
i. This step is done, only to check whether there is any leakage or not.
.

RESULT:
The pipe has been joined together as it was shown in the figure.

SAMPLE EXERCISES IN PLUMBING

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