College Of Technology – Maradana

Type of Programmed: Mechatronics Technology – NVQ 5 / 6

Student names:
K.M. Banduka – 39016

Semester 01 – 2021
Sub Topic: Fitting tools
Assignment No: 01
Date of Submission: 25th January 2022

Signature Of the Student

…………………….

Lecturer: Mr. Kulasekara

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Introduction 5

Tools and their usage 5

Holding tools (Vises) 5
Bench Vise 6
Hand Vise 7
Pipe Vise 8
Leg Vise 9
Pin Vise 10
Tool Vise 11
Care of Vise 11
Striking tools (Hammers) 12
Ball Peen Hammer 12
Cross Peen Hammer 13
Straight Peen Hammer 13
Double-faced Hammer 14
Soft Hammers 14
Cutting tools 15
Chisels 15
Types of Chisel 16
Flat Chisels 16
Cross-Cut Chisels / Cape Chisel 16
Half-Round Chisel 17
Diamon Pointed Chisel 17
Side Chisel 17
Files 18
Size of Files 18
Cut of Teeth 18
Grade of Files 19
The shape of File 20
Flat File 20
Hand File 20
Square File 20
Pillar File 20
Triangular File 20
Round File 21
Half-Rounded File 21
Knife-edge File 21
Warding File 21
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Mill File 22
Needle File 22
Method for filing 22
Cross file 22
Draw Filing 23
Straight Filing 23
Scraper 23
Flat Scraper 23
Triangular Scraper 24
Half-round Scraper 24
Hack Saw 25
Drilling tools 26
Flat Drill 26
Straight Fluted drill 27
Twisted drill 27
Shank drill 28
Cutting angle or angle of lip 29
Rake angles 29
Clearance angles 29
Drilling Machines 29
Types of drilling machines 29
Bench Drill Machine 29
Radial Drill Machine 30
Pillar Drill Machine 30
Column Drill Machine 31
CNC Column Drill Machine 31
Gang Drill Machine 32
Turret Drill Machine 32
Multi-Spindle Drill Machine 33
Micro Drill Machine 33
Deep hole Drill Machine 34
Drill machine Operators. 35
Reaming 35
Tapping 36
Tapper Tap 36
Second Tap 36
Bottom Tap (or plug) 36
Tap wrench (adjustable) 36
Dies and Stocks 37
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Fitting Tools
Introduction
Every workshop has machine tools that are capable of producing work at a faster rate,
but sometimes, work or components must be worked on the bench. Because sometimes it can
be necessary to replace or repair components that must be fit accurately with another
component on reassembly. The accuracy of work done depends upon the experience and skill
of the fitter. The term ‘bench work’ refers to the production of components by hand on the
bench, whereas fitting deals which the assembly of mating parts, through the removal of metal,
to obtain the required fit. Both the benchwork and fitting requires the use of several simple hand
tools and considerable manual efforts.

Tools used in fitting practice may be classified into the following groups
1) Holding tools
2) Striking tools
3) Cutting tools
4) Scraping tools
5) Drilling tools
6) Measuring, Marking, and testing tools

Tools and their usage

Holding tools (Vises)

The holding tools or vises are required to hold the work firmly. Following are the various
types of vises for various purposes.
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01. Bench Vise

(Todorov)

It is used for holding the work and its firmly fixed to the bench with nuts and
bolts. The jaws plats are knurled on one side and fixed in the jaws with the help of
screws and can be replaced when workout. For holding soft materials or finished work
use a soft plate line or covering made of led, fiber, copper, brass, or tin plate that are
fitted all the jaws for giving protective grip in order to prevent the surface of the finished
work from damaging.
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02. Hand Vise

(SERKOV)

It consists of two jaws and hands which are hinged together on a pivot on the
opposite tense. The vise is held in one hand and the required operation is performed by
the other hand. It is used for gripping small objects such as screws rivets, small drills,
keys of lock, and other similar objects.
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03. Pipe Vise

(“What is a hinged pipe vice?”)

It is used for holding pipes sharped or round jobs. The shape of the jaws is like a
“V” shape and it grips a work at four points or its surface.
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04. Leg Vise

(Mayes)

It is generally used in a smith shop. But also suitable for heavy hammering,
clipping, and cutting in fitting shop.
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05. Pin Vise

(“What is a Pin Vice?”)

This is a holding device for small diameter work such as wires and pins it
consists of a fine self-centering chuck on a handle.
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06. Tool Vise

(“Vice Drill - Free photo on Pixabay”)

It is particularly used for small work for piling and drilling. it is made of mild steel.

Care of Vise
1) The vise should be kept clean and free from dust and metal chips by using a brush.
2) The treads and the nuts should be occasionally oiled.
3) The jaws should be covered with soft metal plates.
4) For holding tube temporary used wooden “V” blocks.
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Striking tools (Hammers)

(Donnellan)

The striking tools or hammers are used to strick the job or tool. A hammer consists of a
head striking face, peen, and a shaft. The hammerheads are made from plain steel of about
0.6% carbon and are shaped by stamping or forging.

01. Ball Peen Hammer

(Mishra)

The ball-peen hammer has the peen of the shape of a ball. It is the most common
type of hammer and is mostly used for reverting and chipping.

(“File:Ball-peen hammer 380mm.JPG”)

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02. Cross Peen Hammer

(“File:Warrington hammer.png”)

The cross peen hammer is similar to a ball-peen hammer except that its peen is
like a wedge perpendicular to the handle. It is used for bending, stretching, hammering
into shoulders inside curves.

03. Straight Peen Hammer

(“2 lb. Knife Maker's Hammer (Straight Peen) Version 1.0”)

The straight peen hammer has its peen straight to the Handel stretching or
peening the metal by hammering or fullering.
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04. Double-faced Hammer

The double-faced hammer consists of a head that has two identical faces at both
ends. It is used for striking tools for reverting.

05. Soft Hammers

The soft hammers are used for striking finished surfaces that would be damaged
by the hardened face of a hammer. The two types of soft hammers are

i. Lead Hammers
ii. Row Hide Hammers

The lead hammer has a cost lead head and the row hide hammer has rawhide plugs are
inserted. These plugs can be replaced when they are worn out. The soft hammers may also be
made of wood, hard rubber, copper, and brass.
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Cutting tools
The chief cutting tools using fitting are chisels, axes, or files.

01. Chisels
Chisels are used to cut the metal and are made by forging from cast tool steel of octagon
cross-section.

The various angles form on the chisel are cutting angle, clearance angle, and
rake angle. The most commonly used cutting angle is 60°, but this varies according to
the angle type of material cut.

Material Cutting angle

Aluminium 30°

Copper 45°

Brass 50°

Wrought and mild steel 55-60°

Cast iron 60-65°

Cast steel 70°

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Types of Chisel
01. Flat Chisels

A flat chisel is the most common of the chisel. It is used for chipping flat surfaces,
cutting sheet metal, cutting bars, and reverts.

02. Cross-Cut Chisels / Cape Chisel

It is widely used for cutting grooves on large surfaces. Before using the flat
screw, it is also used for cutting keyways in wheels and shafts.
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03. Half-Round Chisel

It is used for cutting rounds or semi-circular oil grooves in bearings, bosses, and
pulleys.

04. Diamon Pointed Chisel

(“What is the type of chisel you would select for squaring the corners”)

It is used to cut “V” grooves and chip square corns.

05. Side Chisel

(“Chisel Tool Joinery - Free photo on Pixabay”)

It has a cutting-edge bevel on one side only. It is particularly used for chipping
and removing metal in slots.
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02. Files
A file is a hardened piece of high-grade steel with slanting raw teeth it is used to
cut, smooth, or fit metal parts. The files are classified according to size, cut of teeth,
grade, and shape or cross-section of the file.

Size of Files
The size of the file is indicated by its length. It is the distance from the point to the
heel without tang. The length of the file is generally used 200mm to 250mm and 100mm to
200mm for final work

(M)

Cut of Teeth
The files according to the cut of teeth are divided into two groups. Single-cut, and
double-cut.

These files are frequently flat and are particularly used for hard metals.
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Double cut file cut only on the forward stroke it removes metal after use of
general work.

Grade of Files
The single-cut and double-cut files depending upon the pitch of the teeth
(spacing between the rows of teeth) may be classified as rough (R), Bastard (B), Second cut
(SC), Smooth (S), Death Smooth (DS), and Super-fine (SF) or Super smooth (SS).

Grade Effective lop of the file in mm uses

100 150 200 250 300 350 400 450

Number of cuts per 10 mm of length

Rough (R) 10 8 7.1 6.3 5.5 5.3 4.8 4.5 It is used for heavy
reduction and filing
after clipping.

Bastard (B) 18 13 11 10 9 8 7 6 It is used to reduce

bulky work

Second cut (SC) 21 17 16 15 14 13 12 11 It is used for general

work.

Smooth (S) 30 240 20 20 19 18 16 15 It is used for

smoothing surfaces.

Death Smooth 35 33 31 30 28 - - - These are used by

(DS) tool makes and high
accuracy finish work
Super Smooth 63 49 45 42 - - - -
(SS)
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The shape of File

1. Flat File

It has a double cut on both faces and a single cut on both edges. It is mostly
used for general work and for file flat surfaces.

2. Hand File

A hand file is width parallel throughout but its thickness types, both faces
double cut, and one edge single cut. The uncut edge is called the safe edge. It is
used for general surfacing work. More particularly shoulders spoil the adjacent
surface.

3. Square File

It is double cut on all sides and is used for filling corners and slots.

4. Pillar File

It has one or both cut edges and is used for narrow work such as
keyways, slots, and grooves.

5. Triangular File

This is used for file square shoulders or corners and for shaping
wood-working saws.
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6. Round File

The round files are usually double cut on the rough and buster qualities.
The round files are used for opening out holes, producing round corners enders
slots.

7. Half-Rounded File

The half-rounded file flat side is always double cut and the curved side
has a single cut. It is used for filing curved surfaces.

8. Knife-edge File

The knife-edge file has a double cut on both sides flat faces and a single
cut on both edges. It is used for finishing sharp corners of grooves and slots.

9. Warding File
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The warding file is similar to a flat file, but it is thinner and parallels its
thickness. It is used for filing narrow slots.

10. Mill File

A mill file is similar to a flat-file but parallel on both with and thickness
have both edges round. It is single cut and suitable for forming the radius on
sawing and slots.

11. Needle File

The needle files are used for fine work such as pierce designing sheet
metal.

Method for filing

1. Cross file

It is the most common method of filing for general sharping. It is used for the
efficient removal of the maximum amount of metal in the shortest possible time.
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2. Draw Filing

The draw filing is used to remove file markers and for finishing operations.

3. Straight Filing
It is especially useful on long narrow pieces of work which is the width is less
than that of the file.

03. Scraper
A Scraper is a tool with a sharp edge by means of which a very small amount of
metal can be removed. The process of removing metal with a scraper is known as
scraping.

1. Flat Scraper

A flat scraper is the most common and similar to a flat-file. It is used for
producing a perfectly flat surface.
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2. Triangular Scraper

The triangular scraper is made from a worn-out triangular file. It has three
cutting edges. It is used for finishing small holes and for removing sharp
corners and burrs.

3. Half-round Scraper

The half-round scraper is made of a half-round file. It is used for scraping

half of the bearing and curved surface.
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04. Hack Saw

The hack saw is the chief tool used by the filter for cutting rods, bars, and pipes
into designed lengths.
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The best all-around blade for hand use is one with 16 - 18 teeth per 25 mm. For
other special classes of swing.

1. 14 teeth per 25mm for solid brass, copper, and cast iron.
2. 25 teeth per 25 mm for silver steel and thin cast steel rods.
3. 32 teeth per 25mm for sheet metal and tubing.

The following should be kept in mind while using a hack saw

1. The plate must be straight tightly in the frame and steady (about 50 per
minute) should be used.
2. The play gauge of blades may be due to the following reasons,
a. Rapid erratic strokes
b. Too much pressure
c. Blade held too loose in the frame
d. Work not held firmly in the vise.
05. Drilling tools
The drilling tools hold drills that are used for making round holes in the work. The
following 4 types of drills are commonly used.

1. Flat Drill

It is easily made by flattering a round bar of tool steel at one end by forging. The
flat drill can’t be used to drill deep holes because the chips do not come cost to
the hole during operation
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2. Straight Fluted drill

The straight fluted drill is used for marking holes in brass copper and other soft
metals. It’s only this advantage that the chips pack in the tools.

3. Twisted drill

It is the most commonly used variety of drills and is made with two, three, or four
cutting lips.
Two lip grill is used to drill holes into solid metals while the three and four lip drill
is used for enlarging holes previously drilled.
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4. Shank drill

The parallel shank is provided on small size drills (up to 12.5mm) the topper
shank drill has a topper ole called morse taper. The size of the topper on any
perimeter drill depends upon the drill diameter.
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Cutting angle or angle of lip

The cutting angle for ordinary work is 59° and varies from metal to metal.

Rake angles
It is the angle between the flute and the work. It is usually 70° to 75°. This helps
to secure the lip over the correct space to curl the chips.

Clearance angles
It is the angle from by grinding away the heel behind the cutting edge the corn
shape cutting end the point from the lips and varies from 12°-15°.

06. Drilling Machines

A power-operated machine tool which is called the drill in its spindle rotating at high
speeds and when frequently moving linearly against the workpiece produces a hole.

Types of drilling machines

1. Portable drilling machines
2. Bench drilling machines
3. Radial Drilling machines
4. Pillar Drilling machines
5. Gang Drilling Machines
6. Multiple Drilling machines.

Bench Drill Machine

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These are light-duty machines used in the small workshops also called
sensitive drill machines because of their accurate well-balanced spindle.

Radial Drill Machine

Workpiece is marked for exact location and mounted on the work table
drill bit it is then located by moving the radial arm and drill to the marked location.

Pillar Drill Machine

The drill machine usually called pillar drills are similar to the bench drill
machines but have a little longer size and higher capacity. These low-cost drill
machines have tall tabular columns and are used for small jobs and high drilling.
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Column Drill Machine

These box-shaped column-type drilling machines are much more strong,

rigid, and more powerful than the pillar drills. In column drills, the feed gearbox
enables automatic and power feed of the rotating drill at different feed rates as
desired.

CNC Column Drill Machine

These automatic drilling machines have box column type rigid structures
the work table movements and spindle rotation are programmed accomplished
by computer numerical control. These modern drill machines are suitable for a
piece or both production of precision jobs.
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Gang Drill Machine

In this almost single purpose and mew productive machine a number of

(2-6) spindle with drills (Same or different types) in a row are made to produce a
number of holes progressively or Simultaneously.

Turret Drill Machine

Turret drill machines are structurally rigid column types but are more
production-like gang drills by having a pentagon or hexagon turret. The turret
number of drills and similar lords is indexed and move up and down to perform
quickly the desired series of operations progressive.
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Multi-Spindle Drill Machine

In these high production machine tools a large number of drills work

simultaneously. The entire drilling head or repeatedly using the same gig or batch
or lot production of a particular unit.

Micro Drill Machine

This type of tiny drill machines height or within around 200mm is placed
or clamped on a table.
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Deep hole Drill Machine

Very deep holes required for rifle barrels long spindle oil holes in shafts,
bearings connecting rods, such as drilling cannot be done in ordinary
drillers. It needs machines like deep hole drilling machine as gun drilling
machines horizontal axis which is provided with
● HIgh spindle speed
● High rigidly guide
● Pressured cutting oil for effective cooling.
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Drill machine Operators.

● Reaming
● Boring
● Counter boring
● Counter Sinking
● Spot facing
● Tapping

Reaming
IT is a process of smoothing the surface drilled while with a tool. The tool
is called Reamer. Initially, a hole is drilled slightly smaller in size. The drill is
replaced by a reamer, Speed is reduced to half of the drilling.
1. Straight Fluted Reamer

2. Machine Reamer (Spiral Fluted)

3. Expanding Reamer

Before starting the reaming it must be ensured that the reamer is square
with the axis of the hole being reamed in order to obtain the best results. Reamer
should be given a slope and steady motion and lubrication may be used the
reamer is turned only in a clockwise direction even when it is reamed from the
hole.
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Tapping
A tapping is used for cutting internal threads into a hole. The tops are
usually made in sets of 3 to cut any particular size. These are called taper,
Intermediate ( or secondary), and bottom (or plug).

Tapper Tap

Second Tap

Bottom Tap (or plug)

Tap wrench (adjustable)

The process of cutting internal threads into a drill hole using a tap is known as
tapping.

Tapping = Outside diameter - 2 × Depth of thread

After drilling the tapping hole the tapper tap is fixed in the top wrench.
Screw in the hole. For all materials except cast iron, a little oil on the top is
applied to the lubricating. It’s action and improves the finish of the threads. The
tap should be kept in mind that a tap is not turned continuously but after every
half turn, ut should be reversed slightly to clear the thread.
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Dies and Stocks

A tool used for cutting external threads in bars or tubes called a die.

The process of cutting external threads on the crown stems of objects like
bolts, struts, and piles by using a die and stick is known as dieing.
First of all the work is clean of hard scale and its end is slightly chamfered
so that it can enter into a die easily.