Fitting Manual

KAHE - Skill Based Training Courses Fitting Shop
Safety Rules & Unsafe Practices
Remember that “accidents do not occur, they are caused”. With this in mind,
strictly follow the general safety rules given below and safe practices indicated in
brief under each section.
1. Safety first, works next.
2. Know your job and follow instructions.
3. Avoid wearing clothing that might catch, moving or rotating parts. Long sleeves
of shirts, long hair, neck tie and jewellery are definite hazards in the shop.
4. Wear safety shoes. Do not wear canvas shoes; they give no resistance to hard
objects dropped on the feet.
5. Keep the area around machine or work clean.
6. Keep away from revolving work.
7. Be sure that all gaurds are in place.
8. One person only should operate the machine controls.
9. Use tools correctly and do not use them if they are not in proper working
condition.
10. Wear safety goggles when working in areas, where sparks or chips of metal are
flying.
11. Get to know who in-charge of first aid is and where boxes are placed and
where the first aid can be found in case of emergency.
INDEX
Ex. No. Contents
Introduction to Fitting
1. FILING PRACTICE
2. CROSS ANGLE CUTTING PRACTICE
3. SQUARE FITTING PRACTICE
4. V - FITTING PRACTICE
5. SEMI-ROUND FITTING PRACTICE
6. L- ANGLE FITTING PRACTICE
7. PENTAGON FITTING PRACTICE
8. HEXAGON FITTING PRACTICE
9. OCTAGON FITTING PRACTICE
10. DRILLING & TAPPING PRACTICE

INTRODUCTION TO FITTING
Objective:
To familiarise with the basic manufacturing processes and to study the various tools and equipment
used, hands-on training is given in different sections. Essentially student should know the labour
involved, machinery or equipment necessary, time required to fabricate and also should be able to
estimate the cost of the product or job work.
Introduction:
Manufacturing processes are broadly classified into four categories;
(i) Casting processes, (ii) Forming processes,
(iii) Fabrication processes, and (iv) Material removal processes.
In all these processes, components are produced with the help of either machines or manual effort.
The attention of a fitter is required at various stages of manufacture starting from marking to
assembling and testing the finished goods.
Working on components with hand tools and instruments, mostly on work benches is generally
referred to as ‘Fitting work’. The hand operations in fitting shop include marking, filing, sawing,
scraping, drilling, tapping, grinding, etc., using hand tools or power operated portable tools.
Measuring and inspection of components and maintenance of equipment is also considered as
important work of fitting shop technicians.
Fitting Section
1. General safety precaution inside the workshop.

2. Study about first aid.
3. Study of hand tools
4. Study of instruments- Calipers -Scale – Vernier caliper – Vernier height gauge.
5. Marking and punching practice.
6. Hacksaw cutting practice.
7. Filing and fitting practice.
8. Drilling and tapping practice
Filing
List of Equipments Required
1. Power Hacksaw / bar cut machine
2. Hand shearing machine
3. Surface plate
4. Anvil
5. Drilling machine
6. Calipers (Inside / odd leg / outside)
7. Vernier caliper
8. Vernier Height Gauge
9. Bench vice fitted on the table
10. Hand hacksaw Frame
11. Flat rough / smooth file
12. Try angular file
13. Half round file
14. Try square
15. Steel rule
16. Scriber
17. Square file
18. Round file
19. Dot punch / Center punch / Prick punch
20. Hammer
21. Drill Bit (Required size)
22. Tap set (Required size)
23. Tap wrench

a. Flat file: This file has parallel edges for about two-thirds of the length and then it
tapers in width and thickness. The faces are double cut while the edges are single
cut.
b. Hand file: for a hand file the width is constant throughout, but the thickness
tapers as given in flat file. Both faces are double cut and one edge is single cut. The
remaining edge is kept uncut in order to use for filing a right-angled corner on one
side only.
c. Square file: It has a square cross-section. It is parallel for two-thirds of its length
and then tapers towards the tip. It is double cut on all sides. It is used for filing
square corners and slots.
d. Triangular file: It has width either parallel throughout or upto middle and then
tapered towards the tip. Its section is triangular (equilateral) and the three faces are
double cut and the edges single cut. It is used for filing square shoulders or comers
and for sharpening wood working saws.
e. Round file: It has round cross-section. It carries single cut teeth all round its
surface. It is normally made tapered towards the tip and is frequently known as rat-
tail file. Parallel round files having same diameter throughout the length are also
available. The round files are used for opening out holes, producing round comers,
round-ended slots etc.
f. Half-round file: Its cross-section is not a true half circle but is only about one-
third of a circle. The width of the file is either parallel throughout or upto middle
and then tapered towards the tip. The flat side of this file is always a double cut
and curved side has single cut. It is used for filing curved surfaces.
g. Knife edge file: It has a width tapered like a knife blade and it is also tapered
towards the tip and thickness. It carries double cut teeth on the two broad faces and
single cut teeth on the edge. It is used for finishing sharp corners of grooves and
slots.
h. Diamond file: Its cross-section is like a diamond. It is used for special work.
i. Needle file: These are thin small files having a parallel tang and a thin, narrow
and pointed blade made in different shapes of its cross-section to suit the particular
need of the work. These are available in sizes from 100 mm to 200 mm of various
shapes and cuts. These files are used for filing very thin and delicate work
Methods of filing
The following are the two commonly used methods of filing:
1. Cross-filing 2. Draw filing.
Cross - filing.
This method is used for efficient removal of maximum amount of metal in the
shortest possible time. It may be noted that the file must remain horizontal
throughout the stroke (long, slow and steady) with pressure only applied on the
forward motion.
Draw filing.
This method is used to remove file marks and for finishing operations. Here, the
file is gripped as close to the work as possible between two hands. In this filing
method, a fine cut file with a flat face should be used.
Work Bench
Safe Work Practices

The following are some of the safe and correct work practices in bench work and fitting shop:
1. Position the work piece area such that the cut to be made is close to the vice. This practice
prevents springing, saw breakage and personal injury.
2. Use soft jaws when holding finished work surfaces in a bench vice.
3. Position the work in a vice so that it does not overhang into an aisle of other area where a
person might accidentally brush against it.
4. Select the hacksaw blade pitch and set, most suitable for the material and the nature of the
cutting operation.
5. Apply force only on the forward (cutting) stroke, relieve the force on the return stroke.
6. Start a new blade in another place when a blade breaks during a cut. This prevents binding and
blade breakages.
7. Cut a small groove with a file in sharp corners, where a saw cut is to be started. The groove
permits accurate positioning of the saw and also prevents stripping of the teeth.
8. For cutting thin metal strips, clamp them between two pieces of wood. Cutting through both
the wood and the metal prevents the saw teeth from digging in and bending the metal.
9. Wear safety goggles or a protective shield when chipping and driving parts. Flying chips and
other particles may cause eye injury.
10. Grind-off any mushroom that may form on the head of the chisel.
Ex. No.: 1 FILING PRACTICE
Aim: To make a Fit from the given mild steel pieces.
Materials Required: Mild steel flat (40*40*3mm).
Tools and Equipment Required:
1.6”try square 2. 6”sriber 3. Odd leg caliper 4.12”hack saw Frame
4. Blades (12 TPI) 5.10”rough file 6.10”smooth file 7.10”triangle file
8. Knife Edge file 9. Dot punch 10. Ball peen hammer (0.5 Ib)
11. Steel Rule
Sequence of Operations:
1. Filling 2. Marking 3. Punching
4. Sawing 5. Filling 6. Finishing
Procedure:
1. The given mild steel flat piece is checked for given dimensions.
2. One edge of given is filled with rough and smooth files and checked with try square for
straightness.
3. An adjacent edge is also filled such that it is square to first edge and checked with try square.
4. Wet chalk is applied on one side of the flat and dried for marking.
5. Lines are marked according to given figure, using odd leg caliper and steel rule.
6. Using the dot punch, punches are made along the marked lines.
7. The excess materials removed from the remaining two edges with try square level up to half of
the marked dots.
8. Finally buts are removed by the filling on the surface of the fitted job.
Precautions:
1. The perpendicularity of face ends edges is checked perfectly by using try square.
2. Finishing is given by using only with smooth files.
3. Marking is done without parallax error.

Specimen
Job to be done
All Dimensions are in “mm”
Filing Practice
Sl. No. Part Name Actual Obtained Variation
1. A
2. B
3. C
4. D
Result:
Ex. No.: 2 CROSS ANGLE CUTTING PRACTICE
Aim: To make a cross angle cut from the given mild steel pieces.
11. Steel Rule
Procedure:
straightness.
the marked dots.
Precautions:

Specimen Job to be done
Cross Angle Cutting Practice
1. A
2. B
Result:
Ex. No.: 3 SQUARE FITTING PRACTICE

Aim: To make a Square Fit from the given mild steel pieces.
11. Steel Rule
Procedure:
straightness.
the marked dots.
Precautions:

Specimen
Job to be done

Square Fitting Practice
1. A
2. B
3. C
4. D
5. E
6. F
7. G
8. H
Result:
Ex. No.: 4 V - FITTING PRACTICE

Aim: To make a V - Fit from the given mild steel pieces.
11. Steel Rule
Procedure:
straightness.
the marked dots.
Precautions:

Specimen
Job to be done

V - Fitting Practice
1. A
2. B
3. C
4. D
5. E
6. F
7. G
8. H
Result:
Ex. No.: 5 SEMI-ROUND FITTING PRACTICE

Aim: To make a Semi-Round Fit from the given mild steel pieces.
11. Steel Rule
Procedure:
straightness.
the marked dots.
Precautions:
3. Marking is done without parallax error

Specimen
Job to be done
Semi-Round Fitting Practice
1. A
2. B
3. C
4. D
5. E
6. F
7. G
8. H
Result:
Ex. No.: 6 L- ANGLE FITTING PRACTICE

Aim: To make a L-Angle Fit from the given mild steel pieces.
11. Steel Rule
Procedure:
straightness.
the marked dots.
Precautions:

Specimen
Job to be done

L- Angle Fitting Practice
1. A
2. B
3. C
4. D
5. E
6. F
7. G
8. H
Result:
Ex. No.: 7 PENTAGON FITTING PRACTICE

Aim: To make a Pentagon Fit from the given mild steel pieces.
11. Steel Rule
Procedure:
straightness.
the marked dots.
Precautions:

Specimen
Job to be done

Pentagon Fitting Practice
1. A
2. B
3. C
4. D
5. E
Result:
Ex. No.: 8 HEXAGON FITTING PRACTICE

Aim: To make a Hexagon Fit from the given mild steel pieces.
11. Steel Rule
Procedure:
straightness.
the marked dots.
Precautions:

Specimen
Job to be done

Hexagon Fitting Practice
1. A
2. B
3. C
4. D
5. E
6. F
Result:
Ex. No.: 9 OCTAGON FITTING PRACTICE

Aim: To make a Octagon Fit from the given mild steel pieces.
11. Steel Rule
Procedure:
straightness.
the marked dots.
Precautions:

Specimen
Job to be done

Octagon Fitting Practice
1. A
2. B
3. C
4. D
5. E
6. F
7. G
8. H
Result:
Ex. No.: 10 DRILLING & TAPPING PRACTICE

Aim: To make a Drilling and Tapping from the given mild steel pieces.
1.6”try square 2. 6”sriber 3. Odd leg caliper 4.10”smooth file
5. Bench Drilling M/c 6. Dot punch 7. Steel Rule 8. Drill Bit
9. Tapping Bit 10. Tapping Wrench
1. Marking 2. Punching 3. Drilling
4. Tapping 5. Filing 6. Finishing
Procedure:
Steps to drilling the surface hole:
1. Place the drill bit, collar and drill pipe in the hole.
2. Attach the kelly and turntable, and begin drilling.
3. As drilling progresses, circulate mud through the pipe and out of the bit to float the rock
cuttings out of the hole.
4. Add new sections (joints) of drill pipes as the hole gets deeper.
5. Remove (trip out) the drill pipe, collar and bit when the pre-set depth (anywhere from a few
hundred to a couple-thousand feet) is reached.
Steps to tapping the hole:
1. Select the correct tap drill for a specific percentage of thread.
2. Select the correct cutting fluid for tapping.
3. Tap holes by hand or with a drill press.
4. Identify and correct common tapping problems.
a. Taps are used to cut internal threads in holes. Tapping can be performed by hand or with a
machine.
5. A tap wrench or a T-handle tap wrench provides driving torque while hand tapping.
6. To obtain a greater accuracy in hand tapping, a hand tapper is used.

Boring - a drill bit and pipe are used to create a hole vertically into the ground. Sometimes,
drilling operations cannot be completed directly above an oil or gas reservoir, for example, when
reserves are situated under residential areas. Fortunately, a process called directional drilling can
be done to bore a well at an angle. This process is done by boring a vertical well and then
angling it towards the reservoir.
Precautions:
Specimen
Job to be done
Job to be done

Drilling & Tapping Practice
1. A
2. B
3. C
4. D
5. E
6. F
7. G
8. H
Result:

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KAHE - Skill Based Training Courses Fitting Shop

Safety Rules & Unsafe Practices

1. Safety first, works next.

2. Know your job and follow instructions.

5. Keep the area around machine or work clean.

6. Keep away from revolving work.

7. Be sure that all gaurds are in place.

8. One person only should operate the machine controls.

Ex. No. Contents

2. CROSS ANGLE CUTTING PRACTICE

3. SQUARE FITTING PRACTICE

5. SEMI-ROUND FITTING PRACTICE

6. L- ANGLE FITTING PRACTICE

7. PENTAGON FITTING PRACTICE

8. HEXAGON FITTING PRACTICE

9. OCTAGON FITTING PRACTICE

10. DRILLING & TAPPING PRACTICE

Manufacturing processes are broadly classified into four categories;

(i) Casting processes, (ii) Forming processes,

(iii) Fabrication processes, and (iv) Material removal processes.

1. General safety precaution inside the workshop.

List of Equipments Required

1. Power Hacksaw / bar cut machine

2. Hand shearing machine

6. Calipers (Inside / odd leg / outside)

8. Vernier Height Gauge

9. Bench vice fitted on the table

10. Hand hacksaw Frame

11. Flat rough / smooth file

12. Try angular file

13. Half round file

14. Try square

15. Steel rule

17. Square file

18. Round file

19. Dot punch / Center punch / Prick punch

21. Drill Bit (Required size)

22. Tap set (Required size)

23. Tap wrench

The following are the two commonly used methods of filing:

1. Cross-filing 2. Draw filing.

Safe Work Practices

Ex. No.: 1 FILING PRACTICE

Aim: To make a Fit from the given mild steel pieces.

Materials Required: Mild steel flat (40*40*3mm).

Tools and Equipment Required:

1.6”try square 2. 6”sriber 3. Odd leg caliper 4.12”hack saw Frame

4. Blades (12 TPI) 5.10”rough file 6.10”smooth file 7.10”triangle file

11. Steel Rule

1. Filling 2. Marking 3. Punching

4. Sawing 5. Filling 6. Finishing

2. Finishing is given by using only with smooth files.

3. Marking is done without parallax error.

All Dimensions are in “mm”

Sl. No. Part Name Actual Obtained Variation

Ex. No.: 2 CROSS ANGLE CUTTING PRACTICE

Materials Required: Mild steel flat (40*40*3mm).

Tools and Equipment Required:

1.6”try square 2. 6”sriber 3. Odd leg caliper 4.12”hack saw Frame

4. Blades (12 TPI) 5.10”rough file 6.10”smooth file 7.10”triangle file

11. Steel Rule

1. Filling 2. Marking 3. Punching

4. Sawing 5. Filling 6. Finishing

2. Finishing is given by using only with smooth files.

Materials Required: Mild steel flat (40403mm).

Materials Required: Mild steel flat (40403mm).

Materials Required: Mild steel flat (40403mm).

Materials Required: Mild steel flat (40403mm).

Materials Required: Mild steel flat (40403mm).

Materials Required: Mild steel flat (40403mm).

Materials Required: Mild steel flat (40403mm).