Group No: G01

1
Module Name: ME1071
Semester: 2

FAMILIARISATION WITH FITTING OPERATIONS

BY

Index No. Name Marks

200756B DE SILVA T.D.H

Group members

Index No. Name

200354P LOKUGALAPPATHTHI V.H
200009N ABILAASH A.
200414C NAOTUNNA I.H.
200221G HEWAWASAM H.S.S.M.
200649B THILAKARATHNA A.W.G.T.N.
200527B RASHMINA I.D.D.P.
200756B DE SILVA T.D.H.
200025J AMARASINGHA D.A.
200167U FERNANDO P.S.M.
200509X RANASINGHA S.M.

Date of practical session /08/2022

Date of submission

Instructor’s name

Department of Mechanical Engineering

University of Moratuwa
Sri Lanka
 INTRODUCTION

Fitting denotes the production of an article by hand on the bench. Although industry mostly use
machines, fitting work also plays a significant role for finishing a job to the desired accuracy.
Machines can finish a work for good accuracy but there are some minor works must be done by hand
for have good product. Therefore, fitting plays main role in manufacturing. In this process, we use
many kinds of hand tools and perform many operations. Such as cutting, tapping, sawing, chiselling,
filling, scraping etc.

TOOLS AND EQUIPMENT USED

 Steel ruler
 Centre punch
 Divider
 Scriber
 Scriber block
 V block
 Die and die wrench
 Tap and tap wrench
 Hacksaw
 Ball peen hammer
 12’’ rough flat file
 6’’ smooth flat file
 Cold chisel
 L square
 Upright drill press
 Grinding machine
 Bench vies
 Odd leg calliper
 Marking table
 PRODUCING THE BOLT

 First, workpiece was clamped properly, and two faces of the workpiece were filed using rough
file to get smooth faces.
 Then chalk was applied to circular faces of the workpiece and put that on the v block. Then
square was drawn on the face by using try square and scriber. Then intersection point of the
diagonal was found by using steel ruler and marked that point by using centre punch.

 Then 10mm radius circle was drawn around the centre and tangent lines were drawn and
marked them using centre punch as follows.

 Then a 10.5mm diameter hole was drilled through the centre by using 10.5mm drill bit and
bench drill machine.
 Then one side of the workpiece was cut along the marked line using hack saw and material
was removed from the other side until it reached the marked line by using flat cold chisel.
Then both sides were smoothened by using flat file.

 Then internal thread was made by using a suitable tap and the thickness of the workpiece was
decreased until it became 11mm by using flat files.
Prepare the shank

 Then 4 arcs were marked on both sides of workpiece until they just touch each other by
changing the distance of odd leg calliper as follows. Then marked the centre by using centre
punch.

 Then the chalk was applied to curve surface and distances were marked accordingly.

 Two ends of the rod were curvedly filed to obtain the incline surface between 6mm distance,
and the ends as follows.

 The external thread was made on both sides up to the points marked by using stock and die.
 Then these head and shank were fitted at short threaded end. Then the workpiece was clamped
and hammered until it riveted. After that above surface was filled to get a smooth surface.
 SAFETY PRECAUTIONS

WHEN USING HACKSAW,

 Use the hacksaw steadily and strongly.

 Keep the blade horizontally, while cutting and tide the blade to the frame properly.
 Use the entire length while using
 Choose the correct blade for correct use
 Use lubricant to avoid heating and low down the friction
 Clamp the workpiece correctly

WHEN USING FILES,

 Use the entire length

 Use the file horizontally to avoid slipping
 Don’t touch the file surface while filling
 Handle the file properly
 Clamp the workpiece correctly

WHEN USING CHISELS,

 Held the chisels correctly to avoid unnecessary hammering to the fingers

 Sharp the edges before use
 Use the correct angle to do the suitable work
 Always keep the hand away from the chisel edge
 Clamp the workpiece correctly

SELECT HACKSAW BLADES

Teeth per inch Use

14 Large profiles, aluminium, softer metals

18 General workshop projects

24 Steel plate up to 5/6mm thickness (Hard materials)

32 Hollow sections and steel tubing (thin tubing, sheet metal)

Hacksaw blades are selected by choosing the TPI (teeth per inch) for the type of metal that
need to be cut. As the TPI high the cut is more aggressive. The blade's settings can also be applied to
tasks. The advantage of this is that the strength of the "towards" or "away" stroke may be concentrated
to give the user the optimum cutting ergonomics. The teeth can be facing forward or backward. The
18-24 TPI range is almost always used for metal cutting.
 SCRAPERS

Scrapers are used to remove unnecessary material from the workpiece. The operation done by
scrapper is scraping. To precisely fit the parts together, high areas on the surface are eliminated using
the scraping technique.

 Flat Scraper - is used for scraping on flat surfaces

 Half Round Scraper - is used to scrapes the surfaces of bearings
 Three Square Scraper - is used to sharpening the edges of the bush bearings and for scrap the
inner spherical surfaces
 Bullnose Scraper - is used to flat and half round surfaces
 Two Handle Scraper - is used to scrape large flat surfaces and large curved surfaces
 Hook Scraper - is used to scrape the central part of large flat surfaces
 MEASURING INSTRUMENTS

TRY SQUARE

 Try square is used for marking and checking 90° angles on workpieces
 Also, this tool can be used to determine whether a surface is flat or not
 To try a surface is to check its straightness or correspondence to an adjoining surface.

STEEL RULER

 Ruler is used to measure lengths and draw straight lines

 Also, ruler can be used to get distances to divider much easier than ordinary ruler.

MICROMETER SCREW GAUGE

 Used to measure small lengths, thickness, and diameters accurately

 This instrument can be used only to non-flexible materials. Therefore, this instrument can be
use in fitting shop
 HOW TO USE A HACKSAW

The blade should be fitted to frame vertically to have a better cutting and it is much easier to apply
force. When we vertically oriented weight of the frame also help to cut the workpiece easily.

The teeth are designed to face towards one end of the blade, and the blades can be installed in the
handle with the teeth facing forwards or backwards. typically designate the primary cutting stroke
as the "away" stroke since the chips are moved forward during operation, giving a sharper view of
the cut.

You should use both hands to grip the hacksaw. With your dominant hand, hold the hacksaw
handle and extend your index finger so that it points toward the blade's end. When working, keep
your finger extended to guide the saw. Then it is easy to control the hacksaw.
While using the hack saw the weight of the body is resting on one leg and other leg is
straightened. While using hacksaw both feet should touch the ground because then it is easy to
give force to the saw.

First when we cut something, measure and mark the material to be cut accordingly to the
dimensions. Then we must select suitable blade for the application to have a better cutting. The
cutting material should be raised. Clamp the material to the edge of a table in the absence of a vise
to cut the material easily. Before start to saw it is useful to file a guideline to cut the workpiece it
is helpful to avoid slipping.

C channel can be clamped as the opened area is situated bellow as shown below.
I – beam can be clamped as shown below. we need to saw the wide faces first. After sawing those
faces re clamp the beam as middle faceup to be sawn.

Angle iron can be clamped as above which wide face need to be up for sawing. For clamping we
use solid helping piece which has same size and angle to fit the dimensions.

Sheet metal is clamped as wide edge is vertically. In this case the saw blade must be angled in
order to sheet metal is touched by many blades tooth same time.

Special remarks,

 Use the Total length of the blade while sawing is good practise.
 Cutting oil can be used to minimize the friction between hacksaw and the workpiece while
cutting. It helps to avoid unnecessary heat generation.
 Deep cuts can be done using laterally swivelled frame
 We must rest in a suitable position while sawing to avoid unnecessary injuries.
 To have a better sawing, the clamping method we use is very essential.
REFERENCES

 Anon, How to cut metal with a Hacksaw. Metals4U. Available at:

https://www.metals4u.co.uk/blog/how-to-cut-metal-with-a-hacksaw [Accessed September 22,
2022].
 Dwivedi, K., 2022. Types of scrapers and their uses,scraping techniques. Mechical. Available
at: https://www.mechical.com/2021/06/types-of-scrapers.html [Accessed September 22, 2022].