FITTING

INTRODUCTION:

Fitting practice plays an important role in mechanical assembly. The current trend
towards automation in industry heavier demands on the competence of workers engaged in the
assembly, fitting, adjustment, servicing and maintenance of machinery. These must have an
adequate understanding of mechanical, electrical and electronic principles underlying the
construction and operation of modern production equipment.

In fitting shop unwanted material is removed with the help of hand tools. Hand tools are
those tools which are held by hand to perform certain jobs and operations like filing, stamping,
driving a screw, chipping and sawing. Material removal is done for mating, repair and
manufacturing purposes. The shop where these operations are carried out is called the fitting
shop and the person working in fitting shop is called fitter. The bench where these operations
are carried out is known as the fitter’s bench or fitting bench.

The term, "Bench work" refers to the production of components by hand on the
bench, whereas fitting deals with the assembly of mating parts, through removal of metal, to
obtain the required fit.

Both the bench work and fitting requires the use of number of simple hand tools and
considerable manual effort. A fitter should have the complete knowledge of the tools
used in the shop.

The various tools, which can be used, are classified into the following groups according to the
functions they perform during different types of fitting operations.

i) Holding tools ii) Cutting tools iii) Striking tools iv) Scraping tools v) Marking and
measuring tools vi) Drilling tools.

1.2.1 Holding Tools

1.2.1.1 Bench vice: The bench vice is a work-holding device (Fig. 1 .1). It is the most
commonly used vice in a fitting shop. It is fixed to the bench with bolts and nuts. The
vice body consists of two main parts, fixed jaw and a movable jaw. When the vice
handle is turned in a clockwise direction, the sliding jaw forces the work against the
fixed jaw. The greater the pressure applied to the handle, the tighter is the work held.
Jaws are made of hardened steel. Serrations on the jaws ensure a good grip. Jaw caps
made of soft material are used to protect finished surfaces, gripped in the vice. The size
of the vice is specified by the length of the jaws. Jaw plates are made from tool steel and hardened
to HRC 52 approx.

The vice body is made of cast iron which is strong in compression, weak in tension. So
fractures under shock and therefore should never be hammered.

1.2.1.2 V-block with clamp: The V-block is a rectangular or square block with a V-groove on one or
both sides, opposite to each other. The angle o fthe ‘V’ is usually 90o. V-block with a clamp is used to
hold cylindrical work securely , during layout of measuremnts for measuring operation or for drilling
(Fig.1.2.) For this , the bar is placed longitudinally in the V-groove and the screw of V-
clamp is tightened. This grips the rod firmly, with its axis parallel to the axis of the V-groove.

1.2.1.3 C-clamp: This is used to hold work against an angle plate or V-block or any other surface,
when gripping is required (Fig. 1.3). Its fixed jaw is shaped like English alphabet, “C” and the
movable jaw is round in shape and directly fitted to the threaded screw at the end. The working
principle of this clamp is the same as that of the bench vice.

(a) (b)

Figure 1.1 (a) Bench Vice, (b) Cross-sectional view showing parts of Bench Vice
 Figure.1.2. V-Block with clamp Figure.1.3. C-clamp

1.2.2 Marking and Measuring Tools

1.2.2.1 Surface plate: The surface plate (Fig. 1.4) is machined to fine limits and is used for
testing the flatness of the work piece. It is also used for marking out small works and is more
precise than the marking table. The degree of fineness of the finish depends upon whether it is
designed for bench work in a fitting shop or for using in an inspection room. The surface plate
is made of cast iron, hardened steel or granite stone. It is specified by length ' width ' height'
grade. Handles are provided on two opposite sides, to carry it while shifting from one place to another.

1.2.2.2 Angle plate: The angle plate is made of cast iron. It has two surfaces, machined at
right angle to each other (Fig. 1.5). Plates and components, which are to be marked out, may
be held against the upright face of the angle plate, to facilitate the marking. Slots are provided on
the angle plate to clamp the work in position.

Fig.1.4. Surface Plate Fig.1.5.Angle Plate

1.2.2.3 Universal scribing block: This is used for scribing lines for layout work and
checking parallel surfaces (Fig. 1.6). Referring the figure, it may be noted that its spindle can
be quickly adjusted to any angle, by an adjusting screw. In some designs, the base of the block
will have a "V" shaped groove, to enable the block to rest on round bars if required, to set-off the
dimensions from the bar to the surface of the components.

1.2.2.4 Try-square: It is a measuring and marking tool for 90° angle. In practice, it is used
for checking the squareness of many types of small works, when extreme accuracy is not
required (Fig. 1.7). The blade of the try-square is made of hardened steel and the beam, of
cast iron or steel. The size of the try-square is specified by the length of the blade.

Fig.1.6.(b)

Fig.1.6.(a)

Fig.1.6. Universal Scribing Block Fig.1.7.Try Square

1.2.2.5 Scriber: A scriber is a slender steel tool, used to scribe or mark lines on metal work
pieces (Fig. 1.8). It is made of hardened and tempered high carbon steel. The tip of the scriber
is generally ground at 12° to 15°. It is generally available in lengths, ranging from 125 mm to
250 mm. It has two pointed ends. The bent end is used for marking lines where the straight
end cannot reach.
1.2.2.6 Divider: It is basically similar to the calipers except that its legs are kept straight
and pointed at the measuring edge. This is used for marking circles, arcs, laying out
perpendicular lines, bisecting lines, etc. (Fig. 1.9). It is made of case hardened mild steel
or hardened and tempered low carbon steel. Its size is specified by the length of the legs.
 Fig.1.8. Scriber Fig.1.9. Divider

1.2.2.7 Odd-leg caliper: This is also called 'Jenny Caliper' or 'Hermaphrodite'. This is
used for marking parallel lines from a finished edge and also for locating the centre of
round bars (Fig. 1.10). As shown in figure, it has one leg pointed like a divider and the other
leg bent like a caliper. It is specified by the length of the leg upto the hinge point.

Fig.1.10. Odd-leg Calliper

1.2.2.8 Punches: These are used for making indentations on the scribed lines, to make them
visible clearly. These are made of high carbon steel. A punch is specified by its length and diameter,
say as 150 ' 12.5 mm. It consists of a cylindrical knurled body, which is plain for some length at the
top of it. At the other end, it is ground to a point. The tapered point of the punch is hardened over a
length of 20 to 30 mm.

Dot punch: This is used to lightly indent along the layout lines, to locate centre of holes and
to provide a small centre mark for divider point, etc. For this purpose, the punch is ground to a
conical point having 60° included angle (Fig. 1 .11).

Centre punch: This is similar to the dot punch, except that it is ground to a conical point having
90° included angle (Fig. 1.12b). It is used to mark the location of the holes to be drilled.

Fig. 1.11.Dot Punch Fig. 1.11.Center Punch

1.2.2.9 Calipers: Calipers are the measuring device used to measure the distance between two
opposing sides of an object. A caliper can be as simple as a compass with inward or outward-
facing points. The tips of the calipers are adjusted to fit across the points to be measured, the
caliper is then removed and the distance read by measuring between the tips with a measuring too,
such as a rule. These are made of case hardened mild steel or hardened and tempered low
carbon steel. Inside calipers (Fig. 1.13) whose legs are bent outwards are used to measure the
internal size of an object, whereas outside calipers (Fig. 1.13) whose legs are bent inwards are
used to measure the external size of an object.

Fig.1.13. Outside and Inside Callipers

1.2.2.10 Vernier calipers: These are used for measuring outside as well as inside
dimensions accurately (Fig. 1.15). It may also be used as a depth gauge. It has two jaws. One
jaw is formed at one end of its main scale and the other jaw is made part of a vernier scale. In
the figure shown, 19 main scale divisions are divided into 20 equal parts in the vernier scale.
Hence,

Least count of the vernier = 1 main scale division -1 vernier scale division

= 0.05 mm

Fig.1.15. Vernier Callipers

Least count may be defined as the minimum dimension which can be measured by the device. For
measuring the size of an object; it is held between its jaws and noting the main scale and vernier scale
readings; the size can be arrived at.

Vernier caliper is generally made of nickel-chromium steel. Its size is specified by the maximum length
that can be measured by it.

1.2.2.11 Vernier height gauge: The vernier height gauge, clamped with a scriber, is shown in Fig. 1.16.
It is used for layout work. An off-set scriber is used when it is required to take measurements from the
surface, on which the gauge is standing. The accuracy and working principle of this gauge are the same
as those of the vernier caliper. Its size is specified by the maximum height that can be measured by it. It is
made of nickel-chromium steel.

1.2.2.13 Vernier depth gauge: It is used for precision measurement of blind holes, slots, grooves, etc.
(Fig. 1.17). The working principle of this instrument is the same as that of the vernier caliper. It is made of
nickel-chromium steel. Its size is specified by the maximum depth that can be measured by it.

Fig.1.16. Vernier Height Gauge Fig.1.17. Vermier Depth Gauge

1.2.3 Cutting Tools

1.2.3.1 Hacksaw: The hacksaw is used for cutting metal by hand. It consists of a frame, which
holds a thin blade, firmly in position. Hacksaw blade is specified by the number of teeth per
centimetre. Hacksaw blades have a number of teeth ranging from 5 to 15 per centimetre (cm).

Blades having lesser number of teeth per cm are used for cutting soft materials like aluminum, brass
and bronze. Blades having larger number of teeth per centimetre are used for cutting hard materials like
steel and cast iron.

Figure 1.18 shows two types of hacksaw frames and a blade.

Hacksaw blades are classified as: (i) All hard and (ii) flexible types. The all hard blades are made of
H.S.S, hardened and tempered throughout to retain their cutting edges longer. These are used to cut hard
metals. These blades are hard and brittle and can break easily by twisting and forcing them into the
work while sawing. Flexible blades are made of H.S.S or low alloy steel but only the teeth are hardened
and the rest of the blade is soft and flexible. These are suitable for use by un-skilled or semi-skilled
persons.

The teeth of hacksaw blade are staggered as shown in Fig. 1.19 are known as a ‘set of teeth’.
These make slots wider than the blade thickness, preventing the blade from jamming.
 Fig.1.18 Types of Hacksaw Frame with Blade and its terminology

Fig.1.19 Teeth Terminology and set of teeth

1.2.3.2 Chisels: Chisels are used for removing surplus metal or for cutting thin sheets (Fig. 1.20).
These tools are made from 0.9% to 1% carbon steel of octagonal or hexagonal section. Chisels
are annealed, hardened and tempered to produce a tough shank and a hard cutting edge.
Annealing relieves the internal stresses in the metal. The cutting angle of the chisel for general
purpose is 60°. The recommended angles for cutting different materials at cold state are:

Aluminum : 35˚
Mild steel : 55˚
Copper and brass :40o – 45o
Cast iron : 60˚
Cast steel : 70˚

The most commonly used chisels are:

1. Flat chisel
2. Cross cut chisel
3. Half round chisel
4. Diamond point chisel
5. Side chisel

Fig.1.20. Types of Chisels

1.2.3.3 Combination Plier: This is made of high carbon steel by proper hardened and tempering
and is used for cutting as well as for gripping the work (Fig. 1.21).It has small cutting edges in
both the jaws, which make it able to cut small diameter wires. The serrations in the jaws
offer the facility for gripping, it is named as combination plier. Its handles are well insulated,
which makes it suitable for electrical working.

1.2.3.4 Nose Plier: It is similar to combination plier but its gripping jaws have extra length in
tapered form which makes it suitable for gripping small objects and also gripping in narrow
spaces (Fig. 1.22).
 Fig.1.21. Combination Plier Fig.1.22. Nose Plier
1.2.3.5. Reamer: A reamer is used for finishing a drilled hole to an accurate size and to
produce a good surface finish. It is made of HSS. Fig.1.24 gives the detailed terminology and
parts of the reamer There are two types of reamers (1.23).

1. Hand reamer
2. Machine reamer

Fig.1.23. Types of Reamers

 Fig.1.23. Terminology of a Reamer

1.2.3.6 Twist drill: Twist drills are used for making holes. These are made of high speed steel. Both
straight and taper shank twist drills are used (Fig. 1.23). The following are the sizes and designations of
twist drills:

Millimeters from 0.4mm onwards

Inches from 1/64” onwards

Letter drills A to Z

Number drills 60 to 20

Taper shank drill 3 to 100mm

The parallel/straight shank twist drill can be held in an ordinary self-centering drill chuck, say that of a
poratable drilling machine, which has parallel jaws.
 Fig.1.23. Terminology of Twist Drill

The taper shank twist drill has two helical flutes, with a taper shank for handling and driving the drill.
The tapered shank fits into a corresponding tapered bore provided in the drilling machine spindle.

1.2.3.7 Taps and tap wrenches: A tap is a hardened steel tool, used for cutting internal threads in a
drilled hole. Hand taps are usually supplied in sets of three for each diameter and thread size. Each set
consists of a taper tap, intermediate or second tap and plug or bottoming tap as shown in Fig. 1.24. Taps
are made of high carbon steel or high speed steel.

Fig.1.24. Tap wrench and its operation

1.2.3.8 Bench drilling machine: Holes are drilled for fastening parts with rivets, bolts or for
producing internal threads. Bench drilling machine is the most versatile machine used in a fitting shop for
the purpose (Fig.1.25). Twist drills, made of tool or high speed steel are used with the drilling machine
for drilling holes. Following are the stages in drilling work:

Fig.1.25. Bench Drilling Machine

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 hole 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.

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.

1.2.3.9 Portable electric drill: It is the most useful of all pieces of drilling equipment. It is
readily portable and convenient for use. Generally, it is used for drilling holes in small pieces
held in a vice (Fig. 1.26). The capacity of the portable drill is designated by the maximum
diameter of the hole it can drill in steel.

Fig.1.26. Portable Electric Drilling Machine

1.2.4 Finishing Tools

1.2.4.1 Files: Filing is one of the methods of removing small amounts of material from the
surface of a metal part. A file is a hardened steel tool, having slant parallel rows of cutting edges
or teeth on its surfaces. On the faces, the teeth are usually diagonal to the edge. One end of the
file is shaped to fit into a wooden handle. Fig 1.27 shows the parts of a hand file. The hand file is
parallel in width and tampering slightly in thickness, towards the tip. It is provided with double
cut teeth on the faces, single cut on one edge and no teeth on the other edge, which is known as
the safe edge.

Fig.1.27. Parts of File

1.2.4.2 Types of Files: Files are classified according to their shape, cutting teeth and pitch or
grade of the teeth. Fig. 1.28 shows the various types of files based on their shape. Table 1.1 gives
types of files and their description and uses.
Type of file Description of use
Hand file Rectangular in section, tapered in thickness but parallel in width. The
faces have double cut teeth and one of the edges, single cut. The other
edge does not have any teeth and hence called as safe edge file. It is used
for filing a surface, at right angle to an already finished surface.
Flat File Rectangular in section and tapered for 1/3 rd length in the width and thickness.
The faces have double cut teeth and edges single cut. Used for general filing.
Square file Square in section and tapered for 1/3rd length on all faces. All the faces
have double cut teeth. Used for filling corners and slots and also to cut
key ways.

Triangular file Equilateral triangle in section and tapered for 1/3rd length on all faces.
All the faces have double cut teeth. Used for filing internal corners.
Square File Square in section and tapered for 1/3rd length on all faces. All the faces
have double cut teeth. Used for filing corners and slots and also to cut
keyways.
rd
Half round file It has one flat face, connected by a curved face and tapered for 1/3
length. The curved face is not exactly semi-cirular but only a part of
circle. The clat face has double cut teeth and the curved face, single cut.
Used for filing concave surfaces and internal corners.
Round file
Circular cross-section and tapered for 1/3rd length. It has double cut teeth.
Used for filing concave surfaces and circular opening.
Swiss or needle file It is normally 150mm long, with cut teeth. Used for filing corners,
grooves, narrow slots, etc., in intricate work.

Based on the coarseness or pitch of the teeth, files are graded as follows:
a. Rough: It has 8 teeth per cm and it is used for rough work.
b. Baste red: It has 12 teeth per cm.
c. Second cut: It has 16 teeth per cm
d. Smooth: It has 20 to 24 teeth per cm
e. Dead smooth: It has 40 to 48 teeth per cm
 Fig.1.28. Various types of files based on their shape

1.2.4.3 File card: It is a metal brush, used for cleaning the files, to free them from filings, clogged in
between the teeth (Fig. 1.29).

Fig.1.29. File Card

1.2.5 Striking Tools

1.2.5.1 Ball-peen hammer: Hammers are named, depending upon their shape and material and
specified by their weight. A ball-peen hammer has a flat face, which is used for general work and a
ball end, particularly used for riveting (Fig. 1.30).
 Fig.1.30. Ball-peen Hammer Fig.1.31. Cross-peen Hammer

1.2.5.2 Cross-peen hammer: It is similar to ball-peen hammer, except the shape of the peen
(Fig.1.31). This is used for chipping, riveting, bending and stretching metals and hammering
inside the curves and shoulders.

1.2.5.3 Straight-peen hammer: This is similar to cross-peen hammer, but its peen is in –line
with the hammer handle (Fig.1.32).It is used for swaging, riveting in restricted places and
stretching metals.

Fig.1.32. Straight-peen Hammer

1.2.6. Miscellaneous Tools

1.2.6.1 Screw drivers: A screw driver is designed to turn screws (Fig.1.33a).The blade is
bade of steel and is available in different lengths and diameters. The grinding of the tip to the
correct shape is important. A Phillips (star) screw driver is specially designed to fit the head of
Phillips screws. The end of the blade is fluted instead of flattened (Fig.1.33b).The size of a screw
driver is specified by the length of the metal part from handle to the tip.
 Fig.1.33(a)

Fig.133(b)

Fig.1.33. Screw driver

1.2.6.2 Spanners: A spanner or wrench is a tool for turning nuts and bolts. It is usually made of
forged steel. There are many kinds of spanners, as shown in Fig. 1.34. They are named according to the
application. The size of the spanner denotes the size of the bolt on which it can work.

Types of spanners:

1. Single end spanner

2. Double end spanner
3. Ring spanner
4. Box end spanner
5. Adjustable spanner
 Fig.1.34. Types of Spanners

Allen key: It is used for hallow sunk head bolts and screws.

Fig.1.35.Allen key/ wrench

1.3 FITTING OPERATIONS

1.3.1 Chipping: Removing the metal with a chisel is called chipping and is normally used where
machining is not possible (Fig.1.35).While chipping, safety goggles must be put on, to protect
eyes from the flying chips. To ensure safety of others, a chip guard is placed in position. Care
should be taken to see that the chisel is free from mushroom head.
NOTE: For better results, the angle of chipping must be the same throughout the operation.

Fig.1.35. Chipping

1.3.2 Filing: There are several methods of filing, each with a specific purpose (Fig. 2.36). With
reference to the figure, the following may be noted:

1. Holding the file: For heavy work and to remove more metal, a higher pressure is used. For light
and fine work, a light pressure is applied.

2. Filing internal curves: A part of half round file only makes contact as shown, during filing
operation. Movement of the file is indicated by arrows.

3. Cross filing Cross filing is carried out across two diagonals, to produce medium surface finish.

NOTE: The possibility of the surface becoming curved is drastically reduced due to continuous
changing of directions.

4. Draw filing: A smooth file with a flat face is used for this purpose and to produce fine grained
structure.

Fig.1.36. Filling

NOTE: Draw filing is preferred for the edges of long and narrow work pieces. For this, the file is
 placed at right angle to the work and held in both the hands across its body, as close as
possible. During work, the file is pushed backward and forward, along the edge being
filed.

1.3.2.2 Checking flatness and squareness: To check flatness, the try-square is placed as shown
in Fig. 2.37a. No light should be seen between the bottom edge of the square and the top surface of
the work piece, when both are held against light. Similarly, the flatness across thickness of plate is
tested as shown. The squareness of one edge with respect to another reference edge is checked as
shown in Fig. 1.37b.

Fig.1.37. Straightness and Squareness checking

1.4 SAFE AND CORRECT PRACTICES

The following are some of the safe and correct work practices in bench work and fitting shop, with respect
to the tools used:

1. Use the file with a properly fitted tight handle. Never drive a file into its handle with a hammer or other
objects. It may chip or break the file or split the handle. After filing, remove the burrs from the edges of
the work, to prevent cuts to the fingers.

2. Keep hands and tools wiped clean and free of dirt, oil and grease. Dry tools are safer to use than
slippery tools. Do not carry sharp tools in pockets

3. Keep tools sharp and in good adjustment. Dull or poorly adjusted tools must be forced, causing accidents.

4. Hold the pointed tool away from the body, to avoid injury, in case the tool slips.

5. Wear leather shoes and not chappals.

6. Don't wear loose clothes.

7. Remember that a slippery floor is always dangerous.

8. Do not keep working tools at the edge of the table.

9. Put the sharp tool in its proper place, immediately after completion of work with it.
10. Never work in a place where there is no sufficient light.
11. Avoid talking and unnecessary discussions during working time and concentrate only on the work.

12. Position the work piece such that the cut to be made is close to the vice. This practice prevents
springing, saw breakage and personal injury.

13. Position the work in the vice such that it does not overhang into an aisle or other area where a person
might accidentally brush against it.

14. When sawing in a vice, make sure that the work is held tight. A loose vice is dangerous.

15. Cut a small groove with sharp corner of a file, where a saw cut is to be started. The groove permits
accurate positioning of the saw and also prevents slipping of the teeth.

16. Start with a new blade in another place, when a blade breaks during a cut. This prevents binding
and blade breakage.

17. 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.

18. Apply force only on the forward (cutting) stroke and relieve the force on the return stroke.

19. Take the longest possible stroke, but does not allow the blade supporting pins to touch, the job.

20. Do not hold the work piece in hand while cutting.

EXERCISE .NO: 01
T-Fitting

Aim: To make a T-Fitting from the given mid steel work pieces.
Materials Required: Mild steel flat (40*40*3mm).
Tools And Equipment Required:
6”try square , 6”sriber, Odd leg calliper, 12”hack saw Frame 4 Blades (12 TPI),10”rough file,
10”smooth file, 10”Square file, Dot punch, Ball peen hammer (0.5 lb), 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 to straightness with rough and smooth files and checked with try
square.

3. An adjacent is also filled such that is square to first edge and checked with try square.

4. Wet chalk is applied on one side of the flat and dried for making.

5. Lines are marked according to given figure, using odd leg calliper and steel rule.

6. using the dot punch 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.

Result: The T-Fitting is done successfully

EXP NO: 2

V-FITTING

Aim: To make a V-fit from the given two M.S pieces.

Material: Two MS FLAT of size 50x50x5mm
Tools required:
150mm try-square, 250gm ball-peen hammer, dot punch, scriber, chisel, 300mm hacksaw
frame, 18TPI hacksaw blade, 250mm rough and smooth hand files, 6mm rough and
smooth square files, Bench vice and steel rule.
Sequence of operations:

1. The burs in given materials are removed and the dimensions are checked for 50x50x5mm
with steel rule.
2. The pieces are clamped one after the other and outer mating edges are filed and
checked for their flatness, with the help of try-square.
3. The side edges of the two pieces are filed such that, they at right angles to each other
and widths are exactly 48mm.
4. Wet chalk is applied on surfaces of the two pieces.
5. The given dimensions of the V fitting are marked, by using jenny caliper, steel
rule scriber, and the surface plate.
6. The portion to be removed is then marked.
7. Using dot punch, dots are punched along the above scribed lines.
8. Using the hacksaw, the unwanted portions are removed.
9. Now the potions are filed and burrs are removed by filing on the surfaces of fitted job.
Precautions:
1. Never remove chips with hand use a wire brush.
2. Working tool should not be kept at the edge of table.
3. While sawing secure work rigidity.

Result: The required V Fit is thus made by following the above sequences of operations.
EXP NO: 3

HALF ROUND FITTING

Aim: To make a half round fitting from the given two M.S pieces.
Material: Two MS FLAT of size 50x50x5mm
Tools required:
150mm try-square, 250gm ball-peen hammer, dot punch, scriber, chisel, 300mm hacksaw
frame, 18TPI hacksaw blade, 250mm rough and smooth hand files, 6mm rough and
smooth square files, Bench vice and steel rule.

Sequence of operations:
1. The burs in given materials are removed and the dimensions are checked for 50x50x5mm
with steel rule.
2. The pieces are clamped one after the other and outer mating edges are filed and
checked for their flatness, with the help of try-square.
3. The side edges of the two pieces are filed such that, they at right angles to each other
and widths are exactly 48mm.
4. Wet chalk is applied on surfaces of the two pieces.
5. The given dimensions of the Stepped fitting are marked, by using jenny caliper, steel
rule scriber, and the surface plate.
6. The portion to be removed is then marked.
7. Using dot punch, dots are punched along the above scribed lines.
8. Using the hacksaw, the unwanted portions are removed.
9. Now the potions are filed and burrs are removed by filing on the surfaces of fitted job.
Note: The centers of the half rounds are marked by a centre punch. However, after marking
the centre of the half round in the piece Y, the edges of it is further filed till half of the
punched dot is left.

Precautions:

1. Never remove chips with hand, use a wire brush

2. Working toll should not be kept at the edge of the table

3. While sawing secure work rigidity

Result: The semicircular fit is thus made by following the above sequences of operations.