UNIVERSITI TEKNIKAL MALAYSIA MELAKA

SEM 2 2022/2023

SUBJECT: MANUFACTURING PRACTICE

(DMFD1313)

FITTING LAB REPORT

GROUP MEMBERS:

NO. NAME MATRIC NO.

1. MUHAMMAD AMEER IRFAN BIN D052210081

KAMARUL ZAMLEE

2. SHAMALAN A/L SIVAKUMAR D052210010

LECTURER NAME: MADAM SITI RAHMAH BINTI

SHAMSURI
INTRODUCTION

Fitting is the assembly of pieces and the removal of metals to guarantee the appropriate fit after
bringing the dimension and form to the desired size. Fitting is a process used to make objects out of
mild steel. Fitting is a multi-step procedure that includes measuring, cutting, drilling, and finishing. The
whole fitting operation was done by hand. The goal of the fitting process is to show pupils how a
certain product is created. Students obtain hands-on expertise in properly shaping mild steel and
practical skills that bridge the gap between theory and practise by participating in fitting workshops.
They learn to evaluate the measurements of the workpiece and to apply fitting procedures to get the
appropriate size and shape. Furthermore, they learn the value of accuracy in fitting, ensuring that
components fit together effortlessly and operate ideally in the final product.

Furthermore, the objectives include measuring and marking the file edges, file surface, file angle,
hacksaw, drill hole, workpiece punching, and drilling machine after operation. As a result, it is critical
to understand the hand tools used in fitting. Learn how to use a vernier height gauge to measure, read
and comprehend engineering drawings, grasp the principles of a workshop, verify the task for correct
measurements and take safety precautions while opening various machines.

Although machine tools provide speed and efficiency in production operations, there are times when
human hand fitting is required. In some cases, components require exact fitting during reassembly,
which may necessitate replacement or correction. Hand fitting is critical in attaining the ideal fit since it
allows for careful metal adjustment and removal to guarantee proper alignment and operation. Fitting
is the act of assembling matched pieces by meticulously removing material until the required fit is
attained. Because of human participation, the fitting procedure may be carefully controlled and
detailed. Hand fitting includes a variety of processes such as cutting, filing, and drilling. Cutting is the
deliberate removal of surplus material, whether it be cutting parts from a bigger component or altering
the shape to meet specific needs. Filing is used to remove rough edges, improve surfaces, and attain
accurate proportions, resulting in a high-quality product.

A perfect fit between connecting pieces. Drilling may sometimes be necessary to make holes or
apertures in components to accept fasteners or other connecting pieces. Hand fitting necessitates skill
in evaluating measurements, knowing material properties, and utilising suitable procedures to obtain
the required fit. To conduct the essential tasks accurately, a combination of manual dexterity,
expertise, and understanding of hand tools is required.Furthermore, while machine tools improve
production speed and efficiency, manual fitting is still necessary in a variety of scenarios. It allows for
the accurate assembly of components. fits, demanding manual metal removal by cutting, filing, and
drilling. Hand fitting focuses on simple hand tools and human labour, emphasising the necessity of
craftsmanship and experience in obtaining correct fits and assuring the finished product's quality and
performance.
PROCEDURE

Product Drawing

Part A Part B Part A + B

 Procedure Image

1. Mild steel bars were cut into plates

of 60mm 50mm 10mm in
dimensions. Take two pieces of the
plates and label as part A and part
B.

2. Squaring on three sides was

performed using flat file and L
square.

3. The plate was measured with

vernier calliper and vernier height
gauge and mark based on the
product drawing.

4. The steel plate was perform further

cutting (part A and part B) into
56mm 46mm 10mm in dimension
using a hacksaw.
5. The hole location (part A and part
B) was marked using the centre
punch, followed by drilling using a
drill press machine.

6. The steel plate was to perform a

final cutting process into the final
shape (part A and part B) to
remove unwanted portions. For
part A, the hammer and centre
punch was used to remove the
unwanted portion.

7. The product part A and B refined

the dimension by cutting and filling
process.
8. Part A and part B performed the
‘Go/No Go’ test by fitting together.
Redo filling until both parts achieve
‘Go’ result.

9. Chamfer the sharp edges of the

parts.

10. Self-evaluate the dimensions of

the part A and B using the
provided marking form. provided
marking
Result

Part A (Female)

Length A B C D E F G
(mm)

Sample of 45 20 20 25 10 30 9
product

Product 45 29.2 20.4 26 10 28.9 9

produced

Tolerance 0 9.2 0.4 1 0 1.1 0

Part B (Male)

Length A B C D E F G H
(mm)

Sample of 45 15 15 10 25 10 9 35
product

Product 45.4 15 15 10 24.9 10 8.5 34.7

produced

Tolerance 0.4 0 0 0 0.1 0 0.5 0.3

DISCUSSION
1. Which dimension is not within the tolerance limit?
In this fitting lab session,the tolerance that the product has been set is 0.3mm. So there are
some dimensions of the final product that are not actually not achieved in the drawing
required dimensions. We produce 2 different parts of the product such as part A and part B
that can fit perfectly together in the last result in this fitting lab. Firstly, for part A is called
female, the side dimension of the product has a huge gap. Next, at the centre or section D,
the tolerance is so huge. The sample has 25mm and in the final product, we get 26mm so the
tolerance is 1mm.Other than that, for the part B is called male and has some dimension that
can still improve to make it achieve the dimension required. The length of the product is
45.4mm compared to the length of the drawing. The tolerance is 0.4mm. The dimension width
is 8.5.

2. Why does it happen? What is the main factor or process that deviates the dimension of the
product?
There are a lot of factors that cause the dimension to not achieve the settled requirements
just like the drawing given. First and foremost, human error is the main cause that we can
analyse from lab fitting sessions. We lack experience in cutting the workpiece, especially the
sawing process by using hand hacksaws because it is our first time.Sawing is usually used in
cutting the harder material and it also needs the correct portion to use in the sawing process.
In this lab session, we were required to cut the metal to shape it like in the drawing.

3. Which appearance criterion does not meet the required quality?

In this fitting lab session, some of the criteria do not meet the required quality. In Part A the
shape of U is not as perfect as it is. The sides are not straight. As for Part B the appearance
is good but some of the dimension does not fit the tolerance limit

4. Why does it happen? What is the main factor or process that reduces the appearance quality
of the product?
This accident happens due to human error when doing processes that are done without the
help of any automated machines. If this lab session is done with the help of some automated
machine, most errors can be eliminated.

Among the human errors are when cutting the workpiece using the hacksaw. As we were
cutting the piece using the hacksaw, a straight sut was not formed causing the workpiece to
be cutted slanted. Another human is when using the needle file. As we were craving the
workpiece, sometimes the carve is not straight but making a curved shape or carving too
much.
CONCLUSION

As a result, we are grateful and delighted that our final product will come together properly.
My companion and I gained several lessons from this fitting lab session in this manufacturing practice
lab session. First and foremost, we must confirm that the measurement is accurate.

The apparatus is in good shape and has been carefully adjusted before use. In this example, as I
noted in my discussion, we did not verify the vernier height gauge's stylus clamps, which caused the
measurement and the line made by the scribing stylus to be wrong. If the stylus clamps are not
securely clamped, the scribing stylus will become loose and unable to draw a straight line.

After rectifying the error, the scribing line becomes many, making it difficult for me to determine which
line to see and punch with the centre punch. As a result, this lesson instructs us to inspect the
apparatus before using and operating it.

Second, the most important thing we learnt from this lab session is that we must deal with the
tolerance of the two-cut product in order to fit it appropriately. This is critical for my partner and me to
discuss and, of course, require problem-solving abilities in dealing with tolerance to guarantee that
each product we make is right and, more importantly, can fit together. As an example, if my partner
cut more than 1mm, I should cut less than 1mm to ensure that it is within tolerance, and the most
important aspect is to put the male and female parts together. Furthermore, it is critical for us to
always attempt and fail, especially when it comes to fitting things together. So, in order to solve the
problem, we must have a solid collaboration and debate, especially at the final phase, which is to fit
together, where we always trial and error and fill the dimension to make it flatter to match the two
separate sections.

Third, we learnt about hand skills throughout this manufacturing lab session. In this fitting lab session,
we will not only learn about the fitting procedure, but also about other production processes. For
example, sawing, filling, chiselling, and drilling machine operation.

Understanding how to use a drilling machine is vital for making holes of various sizes and depths in
various materials. This ability allows us to drill holes correctly in their workpieces, which may be
required for assembly, attachment, or other functions. We establish a firm foundation in fundamental
manufacturing procedures by studying and practising these hand skills in the fitting lab session. These
abilities are transportable and may be used in a variety of production processes. They not only
improve our ability to do following lab sessions, but they also give essential hands-on experience and
craftsmanship that may be advantageous in a variety of technical sectors and future employment.

The design objective, manufacturing technique, and material selection are the three aspects that
influence a product's dimensions and look quality. Modifications to the design, manufacturing
techniques, or material selection can be made to guarantee that the product meets the specified
dimensional specifications and has the desired aesthetic appeal.