Diploma (Mechanical)

Workshop Practice For 1st Semester

Expt: 1. Practice correctly safety procedures in the workshop.

1. Always listen carefully to the teacher and follow instructions.

2. Do not run in the workshop, you could ‘bump’ into another pupil and cause
an accident.
3. Know where the emergency stop buttons are positioned in the workshop. If
you see an accident at the other side of the workshop you can use the
emergency stop button to turn off all electrical power to machines.
4. Always wear an apron as it will protect your clothes and hold lose clothing
such as ties in place.
5. Wear good strong shoes. training shoes are not suitable.
6. When attempting practical work all stools should be put away.
7. Bags should not be brought into a workshop as people can trip over them.
8. When learning how to use a machine, listen very carefully to all the
instructions given by the teacher. Ask questions, especially if you do not
fully understand.
9. Do not use a machine if you have not been shown how to operate it safely
by the teacher.
10. Always be patient, never rush in the workshop.
11. Always use a guard when working on a machine.
12. Keep hands away from moving/rotating machinery.
13. Use hand tools carefully, keeping both hands behind the cutting edge.
14. Report any damage to machines/equipment as this could cause an
accident.
 AIM: To study the tools used in Fitting Shop
Tools are mainly classified as

i) Holding tools – to hold the work firmly when several operations are being carried out. Ex:
Bench vice, leg vice, clamp, tongs etc.,
ii) Striking tools – to impart the required energy to the tool to cut the material. Ex: Hammer,
mallet.
iii) Cutting tools – used to cut the material. They have sharp cutting edges for the removal of
material. Ex: Chisel, hack was jack plane, drill, shear, file taps.
iv) Marking tools – used to mark the work surface so that the final dimensions can be clearly
laid out the work piece. Ex: Divider, punch, scriber.
v) Measuring tools – used to measure dimensions/angles on the work piece so that the given
size of the model can be measured and marked. Ex: Scale, calipers, bevel protractor.

In the next paragraphs the description of each of the above classified tools has been given. Effort has
been made to cover most of them.

1. Holding Tool

Bench vice :- is a work holding device, fixed to the working bench, ridgidly. It has a fixed end with a jaw
bolted on to the table. A moveable end with a jaw is connected through a screw rod. The screw rod has
a handle on one end. By actuating (rotating the handle) the moveable jaw can be moved towards the
fixed jaw or away from it. Between the gap of the jaws, the workpeice is held rigidly. (fig.13 a shows
this)

Leg vice : It is a work holding device fixed to the working bench rigidly. It contains fixed and moveable
jaws connected to two long leg like members. A screw rod connects the two legs. A spring holds the
legs in tension. A handle provided on to the screw rod is used to actuate the moveable jaw portion. The
gap between the jaws can be increased or decreases to facilitate gripping of the workpiece. It is used for
heavy duty work .

Anvil: It is used to keep the work piece and apply necessary pressure using a hammer. It consists of a
rigid base with a top flat surface and a pointed beak on one side. It is also consists of a small square
hole to keep the work piece while imparting necessary pressure. Using the beak portion of the anvil the
shee metal can be bent into an arc of a circle and necessary bending action can be imparted to the
sheet.

Carpenter’s vice : consists of fixed and moveable jaws. The face of the jaws are provided with wooden
surface backed by metal surface. By using handle the moveable jaw can be moved to an fro and
facilitate clamping of wood.

C-clamp: is a work holding device, in the form of a C. It is handy and portable one. The gap between the
ends of the C can be adjusted using a screw rod and handle.
Tongs : are small work holding devices resembling and ordinary household tong. It has two members
are hinged at a point. It is used to hold and lift the work piece. Sometimes by holding the work in the
tongs, work piece can be hammered.

Collect chuck: consist of three jaws actuated by a bevel pinion. The jaws are held within a casing. The
casing has hold on the outer periphery. The stud end of the pinion can be inserted and by rotating the
handle on the pinion the upper end of the case can be actuated which in turn moves in the jaws upward
or downward. This device is used in a drilling machine to hold drill bits.

V-block: is a small steel block with V-grooves. The cylindrical work piece can be held in the groove and
clamped using C-clamp. It is rectangular or square block with V-groove on one or both sides (opposite
sides). (Fig.13c shows this).

2. Striking Tools

Hammers: are tools used to impart impact energy to the cutting tool while cutting the work piece.
Basically it consists of heavy mass of steel at one end of a wooden handle. The steel end has flat fact on
one side and a peen (cylindrical, spherical or wedge etc.) on the other side. The name of the hammers is
based on the shape of the peen.

Ex: Ball peen hammer, wedge peen hammer.

Mallet : is a hammer all made out of wood. It is used in carpentry work. The same is used in fitters also.

3. Cutting Tool

Hacksaw: is used for cutting of metal. It consists of thin blade with a number of teeth held on to a metal
frame. The blade of the hacksaw is so placed that the teeth points away from the handle. The width of
the cut is always greater than the blade thickness. This facilitate easy cutting. The operator has to move
the blade forward against the workpiece., with pressure and backward without pressure. During forward
stroke, only the material gets removed. While blade makes return stroke no pressure is applied and
there is no cutting action. Here very small chips are formed. Straight cutting is done here.

Chisels: are used for removing bulk of material, by chipping action. Chisels are made of high carbon
steel hardened tempred and annealed. It consists of a cutting edge and a shank. The cutting edge angle
is normally 60o. Thinner chisels are used in carpentry. Tougher hardened steel are used in fitters.

Files: are used for removing small amounts of material from the workpeice.

It is hardened tool having inclined parallel rows of grooves or teeth on its surfaces.One end of it is fitted
into a wooden handle. Varieties of files are used in practice. Flat face, half round file, round file,
triangular file etc, .

Taps : are cylindrical rods with helical threads cut on them. Four axial grooves are provided on the
periphery.
The length is slightly tapered at the end.

They come in 3 sets

i) Starting tap has more taper at the end, has coarse threads.
ii) Intermediate tap has less taper and finer threads.
iii) Final tap has much less taper at the end with finer threads.

They are used in sequence to cut internal threads. A tap wrench is used to hold the taps and by using
hand the necessary rotation of the tap can be given.

Drill bits: These are cutting tools used for creating circular holes in the work piece. A drill but consists of
a shank. Which is plan cylindrical one and a flute end which consist of helical grooves with cutting
edges. The tip of the helical portion ends in the form of a crone,which will provide the necessary cutting
action to the tool. The twist grill or drill bit as it is popularly called as has to be used in a drilling machine
to get the necessary rotating action. By applying pressure on to the work piece through the drill bit
while it is being rotated the hole of required size can be created.

Jack plane: is used in carpentry work. Consists of a rectangular box with slot at the centre to fix a flat
shaped cutting blade with adjustable screws. Thin materials of wood can be removed by this. Smooth
even surface can be created on the work piece by using this.

Wood saw: is used to cut wood. Straight vertical or slant cuts can be made. Cross cut saw is used for
faster and larger jobs. Tenon saw is used for light jobs.

Shears: find use in sheet metal work. Resembles a shear (scissors). Cutting edges. They are also
referred to as snips (hand operated).

4. Marking tools

Divider: consists of two pointed legs hinged at one end. The divider is used to mark or lay off distances
on the piece.

Centre punch & dot punch: are small cylindrical hardened steel pieces with a point at one end. It is used
to punch reference marks on the work piece. They are used to mark the layout lines with a dot and also
locate the centre of the hold to be drilled.

Try Square: is used for checking perpendicularity of adjacent surfaces. It is also used to mark
perpendicular adjacent faces with workpiece. It is used in carpentry and fitters’. It is used for checking
the squreness of adjacent faces of the work. It consists of a blade of hardend steel and a beam of steel.
It is specified by the length of the blade.

Bevel square : This tool is similar to the try squre except the angle between the blade and the stock can
be adjusted for a given angle so that the given angles can be marked easily.
Surface plate: It is flat horizontal hardened steel plate used to hold work piece along with an angle
plate. V-block, scriber etc. to mark the work piece. It helps to mark the surface accuretly. It is used for
checking the flatness of the work piece. It is used to mark the work piece. It is made of cast iron or
hardended steel or granite stone. It is specified by the length, breadth, height and grade.

Scriber block : It consists of a square shaped steel base with a vertical rod attached to it. A small bush
with a projection and wing nut can be slid in the rod, up or down. To the bush a long scribing pin is
attached. It can be swiveled and held at an angle with respect to vertical axis. This length and the angle
of the scriber can be changed. The pin has a pointed end, which is used to mark the work piece.

Marking gauge: It is used in carpentry to facilitate marking on the wooden surface. It consists of sharp
pointer at one end for marking and a square faced adjustable thin wooden block that can be slid on a
square wooden bar. It is provided with a clamp for arresting the square long faced block.

Angle plate: it is plate made of cast iron. It has two adjacent surfaces machined at right angles to each
other. The work piece to be marked is held against the vertical face of the angle plate and then using a
scribing block the surface is marked. The angle plate is used along with a surface plate.

Spring calipers: They are used to check the inside and outside diameter of the work piece, with the help
of a scale. They are referred to as inside and outside calipers. Spring odd leg calipers : it is used for
marking parallel lines from a finished edge. It can also be used to locate the centre of a round bar.

5. Measuring Tool:

Vernier caliper: it is a measuring tool used to measure both outside and inside dimensions of the work
piece. The least value measurable by the Vernier caliper is specified by the term “Least Count of the
caliper”.

Least count (L.C) = value of 1 main scale division – value of vernier scale division.

Outside micrometer: it is used for measuring outside dimensions accurately to 2nd decimal place.

It consists of a liner main scale and a circular vernier scale.

Wire guage: It is used to check the thickness of the sheet metal and it also act as a measuring tool. It
consists of a circular disc with number of slots along its circumference. The thickness of each of the slots
is designated by a integer number and it corresponds to a particular thickness in mm. The sheet metal is
passed through any of the slot that exactly matches and the thickness can be read out in SWG or mm.
Higher the number of the guage thinner is the gauge thickness of the sheet.
 FITTERS
1. What is fitters ?
Fitters is s metal working operation which involve cutting, finishing and assembling of metal
parts.

2. What work material is normally used for the model ?

Mild steel M.S – a low carbon steel with less than 0.25% C. It is also contain other elements –
05-0.8%Si, 0.7=0.9% Mn, 0.05% Mas S & P balance Fe.

3. What is “layout: in fitters ?

The process of laying out or transferring of the dimensions on the work piece is referred to as
layout.

4. What is Try square ? Why is it so called ?

Try square is a tool used for checking the right angles of the adjacent edges of the work piece.
It gets its name since the edges are to be tried again and again for each filing operation to verify
its true perpendicularity.

5. What steps are normally used in preparing a fitter model ?

Various steps involved are :

 First the work piece is made square using filling of edges and checking with Try square.
 Wet chalk paste is smeared on the surface.
 Marking is made using centre of the piece, or the finished edges of the work piece as
reference.
 The given details of dimensions are marked using a scriber and straight edge.
 First all straight lines then in the curves circles, arcs etc. are marked.
 The markings are made using a centre punch and hammer so that permanent reference
mark is present.
 The metal is cut from the mark so that 0.5 – 1mm extra metal is left for final finishing.
 Excess metal is removed from the surface by sawing or chipping.
 Using files, the dimensions are brought to the final specified value.
 If there is drilling and tapping, drilling machine and taps are used to get the internal
threads.

6. What is V-block ?
V-block is a tool to hold circular work piece preventing it from rolling/slipping while marking and
other operations are in progress.

7. What is chipping ?
The process of removing large amount of metal from the work piece surface by using chisel and
hammer is referred to as chipping.
8. What is sawing ?
The process of cutting the work piece into two by metal removal using a saw is referred to as
sawing.

9. What is filling ?
Filling is a cutting operation on metals which involve the removal of metal in small quantities by
hand or by machine using a file.

10. List different types of files

They are classified as:

1. General purpose files – rough, coarse & bastard or

2. as single cut & double cut files or
3. based on shaop
 Flat file
 Square file
 Round file

11. (a) What is the angle of cut in a file ? What is the purpose of grooves/cuts on the file ?
The file surface consists of grooves cut at the angle. The directions of the grooves from the
handle is from right to left down wards called as overcut and from left to right down wards
called upcut when the file is held vertical with the handle upwards. If the file contains both
upcut and overcut grooves then it is referred to as double cut files. The angle of these grooves
depend on the type of metals filled.

11. (b) What angle is used for filling the following materials ?

The normal angle of cut used are:

45 – 60o Bronze

30 – 85o Brass

50 – 60o Al, Steel

These grooves are sharper and provide greater chip clearances for easy filling.

12. What are the specifications of a file ?

Files are specified by their lengths (100-250mm) or (100-315mm).

Shapes – round, flat

Cuts – double cut or single cut.

13. When do you prefer single cut and doublt cut files ?
Single cut files are preferred for softer metals.

Double cut files are preferred for harder metals.

14. List the different types of hammers.

Hammers are classified as

 Ball pen hammer, square face-round face

 Hammer with rubber caps on the face.

15. What is plate? What is sheet ?

When the thickness of the metal is greater than 5mm then it is referred to as place but when
the thickness is less than 5mm then it is refereed to as sheet.

16. How is the size of a try square specified ?

The size of the try square is specified by the length of the blade.

17. Why is the hacksaw blade teeth are staggered ?

Teeth of hacksaw blade is staggered to ensure that the metal powder removed from the cutting
process does not clog and prevent further cutting of the metal. This also ensures that the width
of cut greater than the thickness of the blade.

18. How hacksaw blade is specified ?

The blade is specified by its length 250 or 300mm.

Width 12 or 16mm

Thickness 0.65 or 0.8mm and

Number of teeth per inch (20 per inch etc).

19. What is surface plate?

It is a heavy metal plate with very smooth surface used to hold the work surface. It is used to
mark dimensions using various tools and check the flatness of the work piece.

20. What is twist drill?

A twist drill is a cutting tool used to cut holes in the work piece. The drill is fitted to a drilling
machine. The rotary motion of the drill is used to create a hole.
21. What is the function of a flute in a drill bit ?
It is meant to push the cut metal (chips) to the top during drilling operation.

22. What machine tool is used to create a hole in the plate ?

A drilling machine is used for the purpose.

23. What tool is used for cutting external threads ?

Dies are used for cutting external threads.

24. What tools are used for cutting internal threads ?

Taps are used for cutting internal threads.

25. What are materials used for tools ?

The following materials used for tools:

 Vice – cast iron, carbon steel

 Hacksaw blade – tool steel
 Chisel – medium carbon steel
 Hammer – medium carbon steel
 Twist drill – carbon tool steel, chromium tool steel
 Hand shears – tool steel
 Files – tool steels, chromium steels

26. Name different types of vice.

Bench vice, Machine vice, Pipe vice, Leg vice are the different types.

27. Name the different types of Hammers.

Straight peen hammer, cross peen hammer.

28. List the different types of chisels

Flat chisel, cross cut chisel, diamond point chisel.

29. How are hacksaw blades specified ?

They are specified based on the

i) Pitch of the teeth as

Fine blade – 1mm

Medium blade – 1.4mm

Coarse blade – 1.8mm

ii) Length of the blade

iii) Thickness of the blade
iv) Width of the blade
v) Material of the blade
 30. How are files classified ?
Files may be classified based on the coarseness as

Rough, Bustard, Smooth, Dead & smooth and Super smooth in the decreasing order of
coarseness.

Fitting Model
Aim : To prepare a model as per the given sketch.

Material given : Mild steel plate of L = 52mm, B=50mm, T=5mm 2 nos.

Tools used : Steel scale, try square, Ball peen hammer, Centre punch, Divider, hacksaw with frame, Flat
Chisel, Flat file rough and smooth, Leg vice.

Procedure:

1. Fix the first M.S.piece to the leg vice and file the adjacent edges using rough file.
2. Make the edges perpendicular to each other by filling. Check the same using a Try square.
3. Repeat the same for the other piece and make the adjacent edges perpendicular each other.
4. Now apply a thin layer of wet chalk on the surface of the two pieces and allow it to dry.
5. Mark the layout of the given shape on the two pieces (one forms the male part and the other
female part) –using scale, scriber pin etc., with the help of a surface plate.
6. using centre punch, mark punch marks to get permanent marks on the pieces.
7. Shaded portion is to be removed.
8. Using hacksaw or chisel, remove AA portion and BB portion.
9. Now using hacksaw cut off portion corresponding to V-shape.
10. Using small circular file remove the excess material and slowly finish it. Maintain the
dimensions by checking the same at regular intervals (by matching both the pieces).
11. Match the two surfaces.
12. Measure the critical dimensions.
13. Compare it with the given dimensions and prepare a deviation table.
* Comment on the deviation in the dimensions and the matching of the two portions of the
model.

Dimensions in mm
Portion Male portion Female portion Deviation
Drawing Model Drawing Model
Radius F
Radius M
Edges E