FITTING SHOP

39

23 2.3 CLASsIFICATION OF METALS

Metals are classified into two categories:
FITTING SHOP (a) Ferrous Metals: e.g., Mild steel, Cast iron, High speed steel.
(b) Non-Ferrous Metals: e.g., Copper, Brass, aluminium, tin.
Ferrous Metals

2.1 INTRODUCTION In ferrous metals the percentage of iron is

very high. These are
commonly used for engineering purposes. Some other materials like
Fitting work is a very important work in
unwanted material is removed with the help ofengneering.
In fittina carbon, sulphur, nickel etc., are also mixed into ferrous metals to change
hand tools. It isSnop the properties. Ferrous metals are magnetic in nature and have more
mating, repair and manufacturing purposes. Ihe person working in fO hardness. Some ferrous metals are discussed as under:
shop is called fitter. A fitter should have the complete knowldge of tho n 1. Steel: Steel is a mixture of iron and carbon. It is
used in the shop. Commonly used tools are hacksaw,
files, chiesels tools used in engineering for different
very widely
etc. purposes.
2.2 PHYSICAL PROPERTIES OF METALS
As different types of metals are used in fitting
Table Showing the Classification of Steel is Given Below:
shop, therefore it is
necessary for the students to have some knowledge about the Table 2.1
properties of metals. physical
Steel Carbon Content
1. Lustre: Lustre is the ability of a metal surface to Uses
reflect ight Low Carbon Steel
2. Colour: Colour is the property of a metal to shoW a rays. 0.08 0.25% General engineering
specific surfaca purposes e.g., forging
appearance. It depends upon the composition of the metal.
3. Density: Density is defined as
casting, angles,
the mass per unit volume of the channels etc.,
metal. It is measured in Kg/cm". Medium Carbon Steel 0.25-0.55% Spindles, shafts, pin
4. Melting Point: the temperature at which a metal flows
like a fluid etc.
is known as melting point. Melting point of iron is High Carbon Steel
1539°C. 0.55- 0.8% Chiesels, dies,
5. Boiling Point The temperature at which a metal starts punches etc.
known as boiling point of the metal. boiling is Tool Steel 0.8-1.5% Drills, reamers, tapps
6. Plasticity: By this property of the metal it can be etc.
converted into
required shape and size for commercial use either by application of 2. Alloy steel: Alloy steel is made by combining some percentage
heat or pressure or both. of additional elements into plain carbon steels. The material to
7. Elasticity: It is the property of the metal be mixed depends upon the
by which it can resist properties required from alloy steel.
permanent deformation in new shape and size due to external pressure. Generally strength, hardness, resistance to corrosion are the
8. Stiffness: Due to this property material resists deflection due to main desirable properties. Nickel, Phosphorus, Silicon, Chro-
external load. mium, Molebdenum etc., are added to make alloy steels.
9. Malleability: It is the property by which metal can be 3. Cast Iron: The iron containing carbon more than 2% is known
elongated in as Cast iron. It is a hard and britle material. It is
all directions by the application of external pressure, due to this generally used
for making machine beds, and heavy
property metal can be converted into sheets. parts of machines. It is
of two types:
10. Toughness: Due to this property metal can withstand bending without
1. Grey cast iron 2. White cast iron
failure. Grey cast iron is self lubricated material and is easy to
11. Ductility: By this property metal can be drawn in the form of wires, machine due to free graphites.
without failure. White cast iron is difficult to machine due to the
of cementite. presence
38
 MANUFACTURING PRACTI. FITTING SHOP
41

iron is almost pure iron cntai

Wrought Iron: Wrought low. It is ductil aining 99 9 follows:
of iron. The percentage
of carbon is
drawn into long wir
ductile and soh pifterent types
of vices are as

tool used for holding jobs.

t
It can be rolled
into sheets
or
wires. Iron (a) Bench Vice: It is a
common
jaw plates
are made of wrought iron. rivets consists of a cast iron body and cast iron jaws. Two
of high
Jaw a r e made up
fitted on both the jaws. plates
Steels: High speed steels
are used . are
5. High Speed at high speeds. They
are able o carbon steel and are wear resistant.
tools working Jaw Plate
cutting composition oflain
The
hardness at high temperatures.
4% Chromium, 1% Vanadium
19 vigh speedne
18% tungsten, and Sliding Jaw
steel is
Carbon.
0.7% Body
is used for making springs or bladee
6. Spring Steel: It con
carbon.
tains 0.5-0.6 %
Non-Ferrous Metals Handle
or no quantity of iron
contain negligible are
The metals which
Copper, aluminium, bras, bronze, tin known
as non-ferrous metals.
metals.
ad are
examples of non-ferrouS Flg. 2.1 Bench Vice
the c o m m o n
second slides on a
used in engineering industry co. One jaw is fixed to the body and the
1. Copper: It is widely
ductile having
reddish brown colour. It has
hig
Copper is square threaded screw with the help of a handle.
The jaws are
very soft, in the two jaws and
trical and thermal conductivity.
It is commonly used for opened upto required length, job is placed
of
Nickel, Tin and Cadmium are addod with handle. It is fixed at the four corners
is fully tightened
cal purposes. Sulphur, to it waist height.
to change the properties of copper. the fitters's working bench, and it is upto the
of cast
Brass: Brass is an
of copper and zinc. There is no
alloy (b) Leg Vice: It is made of mild steel and the jaws are
2.
It can be easily soldered this is l
effect bench vice and used
of corrosion on brass. also a steel, it is stronger than the parallel jaw
such as chipping
soft and ductile material. for heavy work. It is used when the operation
or hammering is to be performed. Flange Nut
3. Bronze: It is an alloy of Tin and Copper. Bronze have a aaJood
resistance to atmospheric corrosion and have no effect of wa It is fixed on the Bench or grouted
Jaws
water in a foundation.
on it. It is a wear resistant material.

4. Gun Metal: Gun metal is an alloy of copper, Tin and zinc. Tn (c) Hand Vice: Hand vice is used to
is 10% and Zinc is 2% in it. It is used for making castings grip very small objects. These are
made in different shapes and sizes.
5. Aluminium: It is a soft material with a white colour. It is verv A commonly used hand vice is
light and have good electrical and thermal conductivity. Alu shown in the figure. It consists of Spring
minium is used for electric and decorative work. the two steel legs hinged together
at the bottom. A Spring is provided
2.4 TOOLS USED IN FITTING SHOP
between two legs. The jaws may be
Fitting shop tools are classified as under adjusted from a flange nut. Fig. 2.2 Hand Vice
1. Clamping Tools 2. Measuring and Marking Tools (d) Pin Vice: Pin vice is used to hold wire or small diameter rods.
3. Cutting Tools 4. Striking Tools It is also used for grinding small drills. It consists of a small
5 Drilling Tools 6. Threading Tools chuck made up of tool steel and a mild steel handle.

2.5 CLAMPING TOOLs

The clamping tools that are used in fitting shop are called vices and
this is used for holding the jobs firmly during various fitting operaltions Flg. 2.3 Pin Vice
42
MANUFACTURING PRACTICECE FITTING SHOP
43

hold pipes. a vertin

It consists of Graduated Disc
It is used to cal screw
(e) Pipe Vice: A handle is attachedon the top of the
threads.
with square
is fixed on
the lower eend of the screw. It screw.
A moveable jaw
The jaws of this pipe vice are grips Lock Screw

the pipe at four points.

fixed on the
bench or it can be grouted.
naped.
This vice can be
Handle
Blade

Flg. 2.6 Bevel Protector

Work Piece
be
multi-purpose instrument that
can
Combination Set: It is a
Jaw (c) and a try
Body used as a protector, a level, a mitre, a centre square
square.
Centre Square Protector TrySquare
Pipe Vice
Fig. 2.4 Scale
MARKING TOOLS
2.6 MEAsURING AND
It is used for checking squareness two of Su
(a) Try Square: made upP of steel which is attached
faces. It consists of a blade
base is made up of cast iron or steel. Tv
to a base at 90°. The 11
square is also used for marking right angles and measuring 7 8
Aululalla ulunlnul lulnu Luuludnu mmm uul tD loula
instrument used to draw straigh
straightness of surfaces. is an
It
to a true surface.
lines at right angles

2.7 Combination Set

Fig.
Blade Centre Square: A centre square is used to find the centre of the
(d) arms. For finding
round jobs. it consists of a straight edge and two
out the centre, the round job is placed between two arms.

Stock
Scale
ulubuuululu lu!

Arm
O
Fig. 2.5 Try Square
(b) Bevel Protector: It consists of a steel dial divided into 300 Fig. 2.8 Centre Square
divisions. The dial can be rotated around the centre. The n (e) Scriber and Surface Gauge: Scriber is made up of high carbon
at any angle can be marked or measured by the straight eu steel and is hardened from the front edge. It is used for marking
Straight edge can be slided along the length.
 MANUFACTUAING PRACTITIOCE FITTING SHOP
45

of lines. Scriber made upP

dotted lines. It is
mounted on a verti
(g) Dot Punch: It is used for marking is sharpened.
steel. One end
cal bar is called sur of high carbon stee or high speed of
second end while working. Angle
face gauge. A heavy Hammering is done on the
base is provided at the
the punching end is 60°.
bottom. There is nut Nut
fixed on the bar and
scriber
by this nut the
can be loosened
and
fixed anywhere in the
Scriber Bar
the
Head
bar in this way Punching Edge
inclination can also be
2.11 Dot Punch
Fig.
varied. It is kept on
Centre Punch: It is like a dot punch
except the angle of punch
the surface plate dur h before
used to mark the centre of the hole
ing any measurement.
ing end is 90°. It is
Primarily it is used Base drilling. Punching Edge
along with V block to
draw lines parallel to
a surface. O90
Fig. 2.9 Scriber & Surface Gauge
( Universal Marking
Surface Guage: It consists of a heavy base, a scriber and a 2.12 Centre Punch
Fig.
bar. The scriber can be adjusted to any position with the help the flatness,
Surface Plate: Surface plate is
used for testing
of screw and nut. It is used for marking purposes. It is used to () made up of cast iron or graphite.
draw parallel lines at any desired height with respect to surface trueness of the surfaces. It is
surface. It is
form a very smooth
Its upper face is planed to is used to test
plate. while not in use. It
covered with a wooden cover
is used as a base for V block, sine
a try square and this plate
instruments during measurement.
Spindle bar etc., and other measuring
True Surface

Scriber
O- Nut
Scriber
Stand
2.13 Surface Plate
Fig.
two ribs of metal are
Rocker
G) Angle Plate: It consists of cast iron in which
other. Holes are provided for clamping
standing at right angle to each
Rocker holding and supporting the jobs.
purposes. It is used for
Adjusting Spindle Holes for Clamping Bolts
Screw Nut
Base Guide
Pins
Base

Fig. 2.10 Unlversal Marking Surtace Gauge

Flg. 2.14 Angle Plate
A6 MANUFACTURING PRACTICE 47
FITTING SHOP

(k) V-Block: It is also used for supporting as wel

as
purposes. Round jobs are generally placed on it to marking Lock Nut
line etc. It is made up of cast iron or steel. It is uSed cente
Uclamp to hold cylindrical piece during measurement with
ent. It hol Bar
the job in 'V portion.

V-Block 4

uluu
uiuuiuuiuluid

L Fine Adjustment Nut

Sliding Jaws

Fig. 2.17 Vernler Calllper

of
diameters or thickness
Micrometer: It is used for measuring consists of
(n) It
precision than vernier calliper.
any job. It is
more
end. On the
frame. A hard anvil is screwed on one
a hook type another small
second end a spindle moves to and for carrying diameter
knob the job
Fig. 2.15 V-Block
anvil on Dy turning the spindle
its end. is gradu-
scale. The sleeve on the spindle
0 Steel Rules: These are made up of stainless steel and are is measured from the side of the sleeve
is fitted on outer
available in many sizes ranging from Ft to 2 Ft. These are ated. Another barrel which A
This barrel is also graduated.
marked in inches or millimetres. The edges of streel rules should is attached with the spindle.
side of the spindle.
be protected from rough handiling. ratchet is provided on the
in inches as
micrometers are available
on
The graduation micrometre is
Centimeter Scale count of the
well as in millimetres. The least
.0001" or .01 mm or .05mm.
"T**"T T **"T
generally .001" or
6 8 10 12 16 18
1 2 3 4 5 O) Lock Nut Sleeve

Inch Scale Anvil 0 5 1020

Fig. 2.:6 Steel Rule Spindle Thimble

(m) Vernier Calliper: Vernier Calliper is a precision instrument used Ratchet Stop
for measuring lengths and diameters. It can be used for meas Frame
uring external and internal dimensions. t consists of a gradu
ated bar of rectangular section. It has two jaws, one is moveble
with a small vernier head and the other is fixed. A fine adjust Fig. 2.18 Micrometer

ment nut is also attached to the head. The dimension is meas moves over a
which a pointer
ured by the jaws and is indicated on graduated bar. Minimum Indicator: A round gauge in
(o) Dial is magnified through
movement
links. A
dimension that can be expressed on vernier calliper is known as graduated scale. The a small round
is fitted on the bottom. And
least count. The least count of vernier is 0.001" or 0.02 mm. spring loaded plunger end of the plunger. It touches the
lower
generally. The material of the all parts is stainless steel. point is provided on the used to check the runout
job while measurement. It is generally
or ovality of jobs.
48
MANUFACTURING PRACTCTICE 49
FITTING SHOP
Head for
Zero
Adjustment
Casing
Dial
Main
70
Pointer
50

2. Inside calliper
1. Outside calliper

Plunger Pin

Flg. 2.19 Dlal Indicator

(p) Dividers: These are made up of steel. Dividers have two
having sharp feet. These are hinged at the top. It is used legs Odd
marking arcs, dividing a line or transferring the dimension. for Leg

4. Jenny calliper or odd leg calliper

3. Spring calliper
Legs Fig. 2.21 Callipers

GAUGES
It consists of a stainless steel head and a beam.
(i) Depth Gauge: beam and can be tightened with
the
The head slides along the inches or millimetres.
beam is graduated in
help of a screw. The
Fig. 2.20 Divlder
(qCalipers: It is generally
used to measure the inside
or outside
dameters. It is made in different sizes and
of two bent legs connected at one end shapes. It consists
bolts. The edges are made to by means of rivets or
just touch the
sioh measured with the help of steel job, then the dimen
is Head
typas of callipers: rules. There are four

Beam

Fig. 2.22 Depth Gauge

 51
50 MANUFACTURING PRACTs FITTING SHOP

It is used to check the gap between

(i) Feeler Gauge: two malin Vertical Bar
parts. It consists of a number of metal leaves. These
have different thickness and are fastened together eave
n a
holder. The material of the leaves is stainless steel. smal
Main Scale

Leaves
Fine Adjustment
Screw
Odd
E Leg
LEL
Vernier Scale

Bracket
Clamping Screw
Holder Clamp

Fig. 2.23 Feeler Gauge Scribing Jaw

(ii) Radius Gauge: It is just like a feeler gague. Every leave has Base
different radius.
It is of two types: 2.25 Vernier Height Gauge
Fig.
1. Internal of threads. It
Thread Gauge: It is to check the pitch
used
2. External (V) On every leaf cuts are provided
consists of a number of leaves. in a
It is used to check the radius of outer and inner surfaces. All leaves are assembled
to fit into thread while checking. of the leaves is
material
holder as shown in the figure. The
stainelss steel.

Body

Leaves
N
Body

Fig. 2.24 Radius Gauge

iv) Vernier Height Gauge: It is used to measure the
pieces. it consists of a vertical bar mounted on a
height of work Fig. 2.26 Thread Gauge
heavy base. a wire gauge. It is used to
check
A sliding head with pointer is carried on to the rectangular bar. (vi) Wire Gauge: The figure shows
The bar and head are is made of a steel sheet disc.
graduated. Height gauge is also used as the diameter of wires. It up
marking the lines at specific heights. It is always used by
ing it on surface plate. The base of the height gauge is madeplac
of castiron and the beam is made
up
up of stainless steel.
 52 MANUFACTURING PRACTI
FITTING SHOP

SOO (b) Depending upon thepitch of the teeth

() Coarse (8-14 Teeth per inch)
(i) Medium (16-20 Teeth per inch)
(i) Fine (24-32 Teeth per inch)
hacksaw Frames:
Tvpes of
There are two types of hacksaw Frames:
)Fixed frame (i) Adjustable frame

only one type of blade is used whereas in adjustable

In fixed frame
of the frame can be increased or decreased as per
frame, the length
And the blade from 8" to 14" long can be used in it.
requirement.
Adjustable Frame

Flg. 2.27 Wire Gauge

2.7 CUTTING TOOLS

The tools which are used to remove the materials are known as
cutting tools. These are described below
(a) Hacksaw: Hacksaw is used for cutting of rods, flats etc. The
blade of the hacksaw is made up of high carban steel or
speed steel. And the frame is made from mild steel. The blade Is
high Flg. 2.29 Hacksaw (AdJustable Frame)
in one cen-
placed inside the frame and is tightened with the help of a flange Pitch of hacksaw: It is the number of teeth on blade
nut. The teeth of saw blades are generally forward cut. The hack Hacksaw blades with small pitch are used for thin sections and
timetre.
saw should be used in straight direction otherwise it will resut! In the large pitch are used for thick sections.
breaking of the blade. The length of blade varies from 8" to 14, is clamped
Use of hacksaw: The material to be cut with hacksaw
but generally 12" blade is used in fixed frame hacksaw.
is done with the help of a file. The handle of hacksaw
Into vice. Marking
the frame. Start sawing
Handle Solid Framne is held in right hand and the left hand is kept on
to the horizontal. The
at the marking, keeping the blade slightly inclined
to the horizontal position after starting the cut. The
saw is brought
izontal. The speed
hacksaw should be moved perfectly straight and
of the hacksaw should be 15-25 strokes per minute. Sufficient pressure
should be given to the frame with left hand while in forward stroke.
Water can be used as a coolant for sawing.

Care of hacksaw: The following precautions should be observed

whlle using hacksaw:
Stand Blade Pin Wing Nut 1. Always move the hacksaw in perfect straight and horizontal

Flg. 2.28 Hacksaw (Flxed Frame) direction.

The thickness and width of the blade are 1m.m
2. Never tilt the frame while sawing.
and " respectively. 3. While cutting thin sections wooden piece must be clamped along
Blades are classified as under:
(a) Depending upon the dlrectlon of cut with the work pieces.
() Forward cut 4. Do not use a new blade in the cut made by another blade.
(li) Backward cut
5. The blade should be tightened sufficiently.
 54
MANUFACTUAING PRACTICE FITTING SHOP
55

(b) Files: File is also a multi tooth tool. It is used

material by rubbing it on the metal. Files are to at an angle of

number of sizes, shapes and degree of available in a remove elt files. In single
face. An
teeth are cut in parallel
Cut the
other row of teeth is added in
rows

opposite direction in
coarseness. Cla A0° to the in double cut
is more
cation of files on the basis of grade: ase
case
of double cut files. Material removing rate
(20 Teeth per inch in single cut file.
(i) Rough file than
(i) Bastard (30 Teeth per inch)
(ii) Second cut (40 Teeth per inch)
(iv) Smooth File (50-60 Teeth per inch)
(v) Dead Smooth (100 Teeth per inch)
Handle Tang Heel Face
Tip

cut File Fig. 2.33 Double cut File

Fig. 2.32 Single
the pitch of
number of teeth in one centimetre is called
Length Picth: The 40 in one centimetre.
The number of teeth varies from 10 to
the file.
should be used in perfect horizontal position.
Edge Use of File: The file
files have their teeth pointing forward. So the pressure
Fig. 2.30 Parts of a Flle Most of the work is held in a vice
on the forward stroke only. The
should be applied hand on the handle and left hand
on the
Rough and bastard are the big cut files. These are used for rough after marking. Keeping right
cutting where the material removing is more. These files have bigger teeth is moved to and for with a speed
of 15 to 25 strokes per
front end, file where material removing is more and fine
Dead smooth and smooth files have smaller teeth and are used for files are used,
minute. Rough
finishing
work. Second cut file has the degree of finish midway between for finishging work.
files are used should be kept in mind
while
bastard and smooth file. Care of files: The following points
the files:
Classification on the basis of shape and size: using and storing
should be protected from excessive wearing.
1. The teeth
Files are available in a number of shapes and sizes. The wooden racks.
length of 2. Files should be stored in
files vary from 4" to 14". The shapes available are flat, should be used for cleaning the files.
square, round, 3 File cleaner
triangular, half round etc. When not in use, files should
be coated with oil.
4.
one edge without
teeth. Soft edge
Soft edge File: It is a file having with
workpieces in order to avoid cutting
file is used in complex shaped
of the file.
upper side
the material from
(c) Chiesels: These are used for chipping away
1 2 made up of high carbon steel gener
4 the work piece. These are
flattened and a sharp cutting edge
ally 6" to 8" long. The top is classified on the
is made on the bottom side. Chiesels are
width of the cuttng edge. Commonly
basis of their shape and and dia
flat, cross cut, half round
used forms of chiesels are
under:
is kept as
mond point chiesel. Cutting angle of chiesels
5 6 7 75°
1. Square 2. Triangular or three square (a) For hard materials- 70° to
3. Round 4. Half round
5. Flat 6. Hand file materials- 60°
7. Knife
edge 8. Diamond file. (b) For Medium hard
Fig. 2.31 m a t e r i a l s - 40°
Different shapes of FIles (c) For soft
chipping a large surface. This chiesel is
Classification on the basis of number of cuts A flat chiesel is used for
it is also called as cold chiesel.
Files are classified into fiwo categories i.e., single Used at room temperature so
cut and double
 54

MANUFACTURI PRAC 67
FITTING SHOP

i s called as Ball pean. If the pean is parallel to the handle of the

hammer then it is straight pean hammer. If pean is across the handle
is
of the ashammer then it is cross pean hammer. If
face, then it is double ended hammer.
shape of the pean
same as

Cutting edge
Fig. 2.34 Chlesels
A cross cut
chiesel is narrow
edge is broader than flat chiesel. chiesel and thickness of
It is used for
the cuttim
A half round
chiesel cutting grooves.
is used to cut oil
in the bushes and
grooves Ball pean hammer (b) Straight pean hammer (c) Cross pean hammer
also (a)
clearing small round Fig. 2.36 (a) Maln parts of a Hammer
Corners. Different part of a hammer are also shown in the figure.
A diamond
point Chiesel Pean
chiesel is used for
chipping plates. It is also
used for cleaning the Work
coner of the slots cut at
an angle or of square
Eye
shape 300

Chipping with a chiesel

Neck
The workpiece is
clamped into the vice. The
material is removed with
the help of a chiesel by Vice
Fig. 2.35 Chlpping Face
hammering it with a hand Operation Different types of Hammers
hamme. The chiesel is held Flg. 2.36 (b)
at an
angle to the work
piece. The chiesel
is held firmly while striking it. 2.9 MISCELLANEOUs TOOLS
2.8 STRIKING TOOLS Drill: The tool used for making round holes is called drill. It is made
Hammers are the only tools generally used
for striking in fitting up of high speed steel. The parts of a twist drill are shown as under:
shop. These are used tor There are several types of drills. Most-common type of drill is flat
chipping, titting, punching etc. A hammer
consists of a heavy iron body with a wooden handle.
The weight ranges drill. It is flat in shape at the cutting edge and it is the cheapest drill.
from 0.25 kg to 2 kg. The main It can be used only for driling a hole of smaller depth. Twist drill is
shown in figure. The
types of hammers are as under and are
classilication of a hammer is done based on the another form of drill. It consists of a spiral flute. This is also further
shape of the peans. It the Snape or the pean is ball or
spherical then
 58
MANUFACTURING PRACT
ACTIO
divided into two parts i.e., if the shank is
parallel then 59
FITTING SHOP
shank twist drill. If the shank is tapered then it is it is para
drill. The chips are driven out of the hole Tapered shank
through the flutes 8-10 threads
wwwwwwwww
Body Point
Parallel IILIUUIITTIUII
Shank Land or Margin u wwwwww
1st. taper
Taper tap
3-4 threads

Tapered Shank ww wwwww

Web TITIIIIIIII
Tang w wwwwww 2nd. taper
Intermediate tap
Neck Flute Point Angle
Fig. 2.37 Main Parts of a Drill
(118 in genera wwwwwwwwww

Reamer: Reamer is used to finish the drilled hole. It has IHTIIILIITIIIIII

wwwwwwwww
Cutting edges. Commonly used reamers are shown below: man Plug tap
Threaded handle adjusts jaws

Fig. 2.38 Reamers

P
Counter Sink: Counter sinks aue taper outters used to make the
hole
cone shaped from the upper is it madà jor
fitting screws and naik
Counter Bore: It is used td ghtarge a portion of hole. It is als
made for fitting the heads of boks and serews

Taps: Taps are used for making iri- Holding tap In a tap wrench
Fig. 2.40 (a)
ternal threads. it is inserted into
of the hole at right angle. In hand tap
the face
ping, a set of three taps is used as shown
in the figure. Tap have a toothed body Tap
with a cylindrical
of a flute and the
shape. It also consists
taps are available in a
set of three taps namely Taper, Interme
diate and Plug tap and during tapping
is used in the same order as shown in Teeth 900

Fig. 2.40 (a). The tap is held by tap holder 90

and before tapping hole must be drilled to
size of the root diameter of the thread.
the
Before
Fig. 2.39 Counter-Sink
tapping tap must be held at right
angle to the plane of the work piece as shown in Fig 2.40 (b).

wrench
2.40 (b) Holding
a tap
Fig.
 60

Die and Die Stock

MANUFACTURINC MCFITTING SHOP 61

Die and Die stock are used for

cutting external 5. Scraping 6. Drilling
made from tool steel and have internal threads
threads. Before 7. Tapping 8. Dieing
operation the job is held firm in a vice or
by any other
devices. The proper die is selected for the desired threadin job hold
starting h 1, Marking: It is the first and important operation that is performed in
bench working, since the accuracy of the product depends upon
starting point of the job is chamfered so that the this. Before marking the surface to be marked is quoted by the
justed on the job. By holding the die into die stock, die is nd t
by hand. It is shown in Fig. 2.41. the handle is
r
perty a chalk paste and allowed to dry. Then the job is kept either on
Surface plate or on V block. Then measurement is performed on the
Centre Spring Totat job by appropriate measuring instrument, then marking is done by
Screw scriber, surface gauge and indentification is done by punches.
Stock 2. Chipping: In this operation the material is removed in a stock by
the help of chiesels at room temperature. For large surface first
3 the melal is removed by cros cut chiesel and then remaining
metal is chip off by other chiesels while chapping lubrication is
-- necessary for better life of chiesels. For chipping operation thre
Die things are important first proper selection of chiesel based on
operation, secondly proper grip of the chiesels and appropriate
Fig. 2.41 (a) Dia and Die stock position of standing by the operator. It is a very accurate method
of removing metal in a more quantity with a reasonable finish.
chamfer
3. Sawing: It is an operation which is required to cut the metal in
900
900 different sizes and shapes. It should be done slowly, and standing
in
position is appropriate for this operation. Cutting takes place
forward stroke of hack saw back stroke is ideal. During operation
obtained
full length of the blade should be used. The best result is
if the hack saw blade is fixed in proper direction with correct
tension. Coolant must be used during sawing.
4. Filing: It is an operation which is performed by the help of files. The
exerted in the forward stroke and
pressure for cutting should be
backward stroke is ideal. If the file is moved diagonally on the flat
surface then it gives the best results. Initially a rough file is used
to remove rough
the metal followed by a smooth file for better finish.
Filing by three ways first cross filing for more metal removal
is done
finish.
then followed by straight filing and draw filing for final

5. Scraping: This is a manual operation done in a fitting shop for

In this
producing more accurate finish than obtained by filing.
at a
operation removal of metal takes place in a small quantity
localised portion. In this first a prussian blue is applied on the
Fig. 2.41 (b) Holding a Die stock surface in which higher spots will be noticed. By this operation the
2.10 BENCH WORKING PROCESSES higher spots are removed till entire surface becomes perfectly
It smooth and uniform.
consists of number of
Some of the important operations that are performed manually. an operation done to produce holes either blind
It is or
operations are as follows: 6. Drilling:
1. Marking through ametal piece by the help of drills that are discussed
2. Chipping
3. Sawing earlier. It is done on the drilling machine in which first the job in
4. Filing
held firmly on machine vice. Then the drill is fixed on the machine
 62
MANUFACTURING
and it is lowered by the hand wheel.
PRACTH FITTING SHOP 63

for cooling during operation. Appropriate coolent S

7. Tapping: It is an operation of cutting the interval thread.
help of tap and a tap holder manually. It is already
earlier. ady ddiscuS4
8. Dieing: It is the process of cutting external threads by
of die and die holder. It is also discussed earlier. the he
2.11 DRILLING MACHINES V-Threads
The following drilling machines are generally used in fitting shos
1. Bench driling machine hop: 90
2. Hand Drilling machine
3. Portable drilling machine.
1. Bench Drilling Machine: Figure shows the main parts of ber
oend Square-Threads
drilling machine. It is used for drilling, reaming, counter sinkin
and counter boring etc.
290

Main Drive
Feed Electric
Drive
Motor
Acme Threads
Drill
Spindle 2.43 Various types of Threads
Fig.

Table 2.12 SCREW THREADS

Column
many types of threads available in engineering.
There are
The thread is gen-
1. British standard whitworth Threads (B.S.W):
used on bolts and nuts. It is a V-shaped
thread having an
erally
Crank angle of 55°.
Handle are also V-shaped threads. Thread
Base 2. Metric Threads: Metric threads
angle is kept 60° in metric threads.
Fig. 2.42 Drilling Machine
Such threads
2. Hand Drilling Machine: It is used for 3. Square shape of the thread is square.
Threads: The
making very small holes threads. Wear and tear is also
The spindle of this machine is rotated are less stronger than V-shape
by a crank. It is pressed from less. These are used in screw jacks.
the handle with left hand while crank is rotated with hand.
right form of square threads. These
3. Portable Drilling Machine: It is used for medium size holes 4. Acme Threads: It is a modified
threads. The thread angle of
The machine is compact and small in size. It can threads are stonger than square
be brough On lead screw shaft of lathe, acme threads
near to the work place for acme threads is 29°.
drilling. A small motor is attached
on the drilling machine. are used.
 64
MANUFACTURING PRACTCTICE FITTING SHOP
65

S. No. V-Threads
Square Threads Depth Gauge (a) Head Cast steel
1. These are generally These are 13.
used for (b) Beam Stainless steel
used for screws, and shaft threads. spindle
nuts and bolts. Feeler Gauge (a) Leaves Spring steel
14.
V-Threads offer more (b) Body Mild steel
2. Square threads offer
resistance to motion resistance to motion less 15. Radius Gauge (a)Leaves Spring steel

(b) Body Mild steel

3. V-threads have more strength Square threads have less
Varnier height (a) Base Cast iron
strength 16.
(b) Beam Stainless steel
gauge
4. These threads can be cut easily These threads can Stainless steel
not be (c) Head
easily cu High carbon steel
(d) Scriber
High carbon steel
2.13 MATERIAL CHART 17. File (a) Body
High carbon steel
(b)Tang
(c) Handle Wood
S. No. Name of Tool Part Name Material
(a) Frame Mild steel
1. Bench Vice Hacksaw
(a) Body Cast iron 18.
carbon steel or
(b) Jaw
(b) Blade High
Cast iron High speed steel
(c) Jaw Plates High Carbon steel High speed steel
(d) Handle Mild steel 19 Chiesel
High carbon steel
(e) Box Nut Gun Metal
Cast steel
2. Hand Vice (a) Jaw Cast Iron 20. Hammer (a) Body
(b) Handle Wood
(b) Spring Spring Steel High speed steel
3. Pin Vice (a) Handle Mild steel 21. Drill
High speed steel
(b) Chuck Tool steel 22. Reamer
High speed steel
4. Try Square (a) Blade 23. Tap
Stainless steel
(b) Base Cast iron or cast steel
5. Scriber TEST QUESTIONS
High carbon steel
6. Centre Punch
High carbon steel
construction of
High speed steel 1. With the help of suitable sketches, explain
the
7. Surface Plate Cast iron bench vice
() Fitters parallel jaw [June 1987]
8. Graphite (i) Surface plate.
V-Block Cast iron
9 Divider 2. Write short notes on:
High carbon steel
10. Foot Rule (i) Singlecut and double cut files
Stainless steel to pitch.
Spring steel (ii) Grading of files according
11. Vernier calliper file [June 1987]
Stainless steel (ii) Soft edge
T2 Micrometer instruments:
(a) Frame Cast steel 3. Sketch and describe the following
(b) Anvil High carbon Steel (i) Vernier Calliper
(c) Spindle Medium carbon steel (i) Universal bevel protector
[Nov. 1987]
(ii) Dial test indicator
 66
MANUFACTURING PRACTITICE FITTING SHOP 67
4. How are files classified ? Name and explain various tunen.. Aluminium Handle
t files No. 1
fieg Job
5. What are different parts of combination set and their [Nov. 196 4-counter
use? shunk hole
93
6. (a) Sketch and describe engineers trysquare [June 1988) 30

(b) How will you test its truness with the help of a surace te?
7. Describe the following with sketches: [Nov. 1988 25-
100
() Taps and Dies
Swaing and filing practice
Job No. 2
(i) Screw pitch gauge
(ii) Radius gauge
[Nov. 1988
8. (a) What difference between
is the 'tapping' and 'Dieing' operation
in fitting shop?
[Nov. 1986
-12t12- N

(b) How many types of punches are used in fitting shop ?

(c) Why are flutes provided on a twistdrill ?
[June 1989
9. (a) Name the different types of vices which are used in fiting
shop? 24
(b) With the help of sketch, explain the construction and
working of
"fitters parallel jaw bench vice".
[Nov. 1989
10. What is the advantage of an adjustable hacksaw frame over the
solid hacksaw frame. 48
[Feb. 1991

VIVA QUESTIONS Job No. 3 Drilling, Counter-Striking and Counter-Boring

1. Classify the tools used in fitting shop.

2. Name any three holding devices in
3. What is the material of
fitting shop. Counter
centre punch? sunking
4. What is the point angle of a dot
What is the material of a surface
punch?
plate?

-
6. Name any two
measuring instruments used in fitting shop.
7. Name the different
types of chiesels.
8. What is the material of file and
hacksaw blade?
9 What is the cutting angle of a
chiesel? Tapping
10. Name the important 12 i-12
types of files.
ANSWERS: (1) Holding tool, Marking tool,
tocl, Stirking tool, Threading tool, (2) Bench Measuring tool, Cutting
Vice, Pin vice, Hand vice
(3) High carbon Steel (4) 60° (5) Graphite, Cast iron 60
(6 Vernier
Micrometer (7) Flat Chiesels, Cross cut chiesel, Diamond point Calliper
chiesel
(8) High Carbon Steel (9) 30° (10) Rough, Bastard, smooth,
round, triangular. Flat, Square
68
MANUFACTURING PRACTIC
Job No. 4 Square Fitting
3
WELDING SHOP

3.1 INTRODUCTION

Welding is a process of joining two materials with the help of heat

13.5
less
or pressure or by some other means. The cost of welding is very
to other and forms strong joint. For this
as compared processes a
reason it is largely used in the following fields of engineering
1. Manufacturing of machine tools, autoparts, cycle parts C.

2. Fabrication of farm machinery and equipment.

9.5 3. Fabrication of buildings, bridges and ships.
4. Construction of boilers, furnaces, railways, cars, aeroplanes,
55 rockets and missiles.
5. Manufacturing of television sets, refrigerators, kitchen cabinets
etc.
Main purpose of welding is to join two pieces. For this initially
filler
Job No. 5 Dieing Practice temperature of the parent metal is raised upto melting point, then
is used as a suppliment for molten pool. A homogenous mixture
metal
is formed at the joint then it is allowed to solidifty to form a weld.
This
is fusionwelding.
In next process the ends to be joined are brought to the plastic
stage and then apply external pressure to join them. It is pressure
welding. In both the above cases the source of heat is as follows for
O00 ex it is furnace in forge welding, it is gases in gas welding it is electrical
energy in Arc welding, it is chemical reactions in Thermit welding etc.
3.2 TYPES OF WELDING
Many types of welding processes has been developed depending upon
the field of their applications. Some of the processes are listed below:
1. Forge welding 2. Gas welding
3. Electric arc welding 4. Spot welding
5 Seam welding 6. Thermit welding
7. TIG welding 8. MIG welding
9. CO-MIG welding 10. Plasma arc welding
3.2.1. Forge welding: This welding is done by the black-smiths. In
this two similar metal pieces are heated upto the plastic stage in the
furnace. Then it is hammered so that a homogeneous mixture is formed
69