Meghnad Saha Institute of Technology

Work Instruction

1. EXPERIMENT NO.: ES-ME192/03/Fitting

2. NAME OF EXPERIMENT: Making a V-fitting joint of two MS plates as per

drawing

3. OBJECTIVE: To make a mating component separately of mild steel plate

using different operations in fitting shops.

4. PRINCIPLE: Machine tools are capable of producing work at a faster rate, but
there are occasions when components are processed at the bench.
Sometimes, it becomes necessary to replace or repair components which
must fit accurately with another component on reassembly. This involves a
certain amount of hand fitting. The assembly of machine tools, jigs, gauges,
etc, involves a certain amount of bench work. 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 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 a number of simple hand tools and considerable manual
effort. The operations in the above works consist of filing, chipping, scraping,
sawing, drilling, and tapping.
5. APPARATUS / UTILITIES REQUIRED:
HOLDING TOOLS
1 Bench vice
The bench vice is a work holding device. It is the most commonly used vice in
a fitting shop. The bench vice is shown in Figure 1.1.

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Figure 1.1: Bench Vice

It is fixed to the bench with bolts and nuts. The vice body consists of two
main parts, fixed jaw and movable jaw. When the vice handle is turned in a
clockwise direction, the sliding jaw forces the work against the fixed jaw. Jaw
plates 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.
The vice body is made of cast Iron which is strong in compression, weak in
tension and so fractures under shocks and therefore should never be
hammered.

2 V‐block
V‐block is a rectangular or square block with a V‐groove on one or both sides
opposite to each other. The angle of the ‘V’ is usually 900. V‐block with a
clamp is used to hold cylindrical work securely, during layout of
measurement, for measuring operations or for drilling for this the bar is faced
longitudinally in the V‐Groove and the screw of V‐clamp is tightened. This grip
of the rod is firm with its axis parallel to the axis of the v‐groove.
3 C‐Clamp
This is used to hold work against an angle plate or v‐block or any other
surface, when gripping is required. Its fixed jaw is shaped like the 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.
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Figure 1.2: V‐block Figure 1.3: C‐clamp

MARKING AND MEASURING TOOLS
1 Surface plate
The surface plate is machined to find limits and is used for testing the
flatness of the work-piece. It is also used for marking out small boxes and is
more precious than the marking table. The degree of the finish depends upon
whether it is designed for bench work in a fitting shop or for use in an
inspection room; the surface plate is made of Cast Iron, hardened Steel or
Granite stone. It is specified by length, width, height and grade. Handles are
provided on two opposite sides, to carry it while shifting from one place to
another.

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Figure 1.4: Surface plate Figure 1.5: Angle plate

2 Try square
It is a measuring and marking tool for 900 angles .In practice, it is used for
checking the squareness of many types of small works when extreme
accuracy is not required .The blade of the Try square is made of hardened
steel and the stock of cast Iron or steel. The size of the Try square is specified
by the length of the blade.
3 Scriber
A Scriber is a slender steel tool, used to scribe or mark lines on metal work
pieces. It is made of hardened and tempered High Carbon Steel. The Tip of
the scriber is generally ground at 120 to 150.
It is generally available in lengths, ranging from 125mm to 250mm .It has two
pointed ends; the bent end is used for marking lines where the straight end
cannot reach.

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Figure 1.6: Try square Figure 7:

4. Scriber
5. Odd leg Caliper
This is also called ‘Jenny Caliper’ or Hermaphrodite. This is used for marking
parallel liners from a finished edge and also for locating the center of round
bars; 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 up to the hinge point.
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, by setting lines. It is made of case hardened mild
steel or hardened and tempered low carbon steel. Its size is specified by the
length of the leg.

7. Trammel
Trammel is used for drawing large circles or arcs.
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’ 12.5mm). It consists of a cylindrical
knurled body, which is plain for some length at the top of it. At the other end,
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it is ground to a point. The tapered point of the punch is hardened over a

length of 20 to 30mm.
Dot punch is used to lightly indent along the layout lines, to locate center of
holes and to provide a small center mark for divider point, etc. for this
purpose, the punch is ground to a conical point having 60° included angle.
Center punch is similar to the dot punch, except that it is ground to a conical
point having 90° included angle. It is used to mark the location of the holes to
be drilled.

9. Calipers
They are indirect measuring tools used to measure or transfer linear
dimensions. These are used with the help of a steel Rule to check inside and
outside measurements. These are made of Case hardened mild steel or
hardened and tempered low carbon steel. While using, the legs of the caliper
are set against the surface of the work, whether inside or outside and the
distance between the legs is measured with the help of a scale and the same
can be transferred to another desired place. These are specified by the length
of the leg. In the case of the outside caliper, the legs are bent inwards and in
the case of the inside caliper, the legs bent outwards.

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Figure 1.10: Calipers

10. Vernier Calipers
These are used for measuring outside as well as inside dimensions
accurately. 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.

Figure 1.11: Vernier caliper

11. Vernier Height Gauge
The Vernier Height gauge clamped with a scriber. It is used for Layout work
and offset scriber is used when it is required to take measurement 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 calipers. Its size is specified
by the maximum height that can be measured by it. It is made of
Nickel‐Chromium Steel.

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Figure 1.12: Vernier Height gauge

CUTTING TOOLS
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 centimeter. Hacksaw blades have a number of teeth
ranging from 5 to 15 per centimeter (cm). Blades having a lesser number of
teeth per cm are used for cutting soft materials like aluminum, brass and
bronze. Blades having a larger number of teeth per centimeter are used for
cutting hard materials like steel and cast Iron.
Hacksaw blades are classified as (i) All hard and (ii) flexible type. 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.

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Figure 1.13: Hacksaw frame with blade

The teeth of the hacksaw blade are staggered, as shown in figure and known
as a ‘set of teeth’.
These make slots wider than the blade thickness, preventing the blade from
jamming.

Figure 1.14: Set of teeth

2 Chisels
Chisels are used for removing surplus metal or for cutting thin sheets. These
tools are made from 0.9% to 1.0% carbon steel of octagonal or hexagonal
sections. Chisels are annealed, hardened and tempered to produce a tough
shank and hard cutting edge. Annealing relieves the internal stresses in a
metal. The cutting angle of the chisel for general purpose is about 60°.

Figure 1.15: Flat chisel

3 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. The parallel shank twist
drill can be held in an ordinary self – centering drill check. The taper shank
twist drill fits into a corresponding tapered bore provided in the drilling
machine spindle.

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Figure 1.16: Twist drills

4 Taps and Tap wrenches
A tap is a hardened and steel tool, used for cutting internal thread in a drill
hole. Hand Taps are usually supplied in sets of three in each diameter and
thread size. Each set consists of a tapper tap, intermediate tap and plug or
bottoming tap. Taps are made of high carbon steel or high speed steel.

Figure 1.17: Taps and tap wrench

5 Dies and die‐holders

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Dies are the cutting tools used for making external thread. Dies are made
either solid or split type. They are fixed in a die stock for holding and
adjusting the die gap. They are made of Steel or High Carbon Steel.

Figure 1.18: Dies and die holder

6 Bench Drilling Machine
Holes are drilled for fastening parts with rivets, bolts or for producing internal
thread. Bench drilling machine is the most versatile machine used in a fitting
shop for the purpose. Twist drills, made of tool steel or high speed steel are
used with the drilling machine for drilling holes.
Following are the stages in drilling work
1. Select the correct size drills, put it into the check 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 of the location of the pole and mark it with a center punch.
4. Hold the work firmly in the vice on the machine table and clamp it directly
on to 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.

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8. On completion of drilling, retrace the drill out of the work and put‐off the power
supply.

Figure 1.19: Bench drill

FINISHING TOOLS
1 Reamers
Reaming is an operation of sizing and finishing a drilled hole, with the help of
a cutting tool called reamer having a number of cutting edges. For this, a hole
is first drilled, the size of which is slightly smaller than the finished size and
then a hand reamer or machine reamer is used for finishing the hole to the
correct size.
Hand Reamer is made of High Carbon Steel and has left‐hand spiral flutes so
that it is prevented from screwing into the hole during operation. The Shank
end of the reamer is made straight so that it can be held in a tap wrench. It is
operated by hand, with a tap wrench fitted on the square end of the reamer
and with the workpiece held in the vice. The body of the reamer is given a
slight taper at its working end, for its easy entry into the hole during
operation, it is rotated only in clockwise direction and also while removing it
from the whole.

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Figure 1.20: Reamers

2 Files
Filing is one of the methods of removing small amounts of material from the
surface of a metal part. A file is hardened steel too, having small 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. The figure shows various parts of a hand
file. The hand file is parallel in width and tapering 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 a safe edge.

Figure 1.21: Parts of a hand file

Files are classified according to their shape, cutting teeth and pitch or grade
of the teeth. The figure shows the various types of files based on their shape.

Figure 1.22: Single and double cut files

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Needle file
Figure 1.23: Types of files
MISCELLANEOUS TOOLS
1 File card
It is a metal brush, used for cleaning the files, to free them from filings,
clogged in‐between the teeth.

Figure 1.24: File card

2 Spirit level
It is used to check the leveling of machines.
3 Ball‐ Peen Hammer
Ball‐ Peen 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.

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Figure 1.25: Ball peen hammer

4 Cross‐Peen Hammer
It is similar to a ball peen hammer, except the shape of the peen. This is used
for chipping, riveting, bending and stretching metals and hammering inside
the curves and shoulders.
5 Straight‐Peen Hammer
This is similar to cross peen hammer, but its peen is in‐line with the hammer
handle. It is used for swaging, riveting in restricted places and stretching
metals.

:
Straight peen hammer Figure 1.26:
Cross peen hammer

6 Screwdriver
A screwdriver is designed to turn screws. The blade is made of steel and is
available in different lengths and diameters. The grinding of the tip to the
correct shape is very important.
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A star screw driver is specially designed to fit the head of star screws. The end
of the blade is fluted instead of flattened. The screwdriver is specified by the
length of the metal part from handle to the tip.

Figure 1.28: Screw drivers

7 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. They are named according to
the application. The size of the spanner denotes the size of the bolt on which
it can work.

6. SAFETY:
The following are some of the safe and correct work practices in bench
work and fitting shop, with respect to the tools used
1. Keep hands and tools wiped clean and free of dirt, oil and grease. Dry
tools are safer to use than slippery tools.
2. Do not carry sharp tools in pockets.
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3. Wear leather shoes and not sandals.

4. Don’t wear loose clothes.
5. Do not keep working tools at the edge of the table.
6. Position the workpiece such that the cut to be made is close to the vice.
This practice prevents springing, saw breakage and personal injury.
7. Apply force only on the forward (cutting) stroke and relieve the force on
the return stroke while sawing and filing.
8. Do not hold the workpiece in hand while cutting.
9. Use the file with a properly fitted tight handle.
10. After filing, remove the burrs from the edges of the work, to prevent
cuts to the fingers.
11. Do not use vice as an anvil.
12. While sawing, keep the blade straight; otherwise it will break
13. Do not use a file without a handle.
14. Clean the vice after use.

7. DISPOSAL: N.A.
8. REPORT WRITING:
Attach the rough note with your final report.
The front page of the report shall be as per the format shown in Annexure.
Report sheet must contain the following article in order.
Experiment No
Name of Experiment
Objective of the Experiment
Principle
Apparatus used
Procedure
Results & Discussion
Calculation (if needed)
9. ASSIGNMENT QUESTIONS:
1. With a neat sketch show different parts of a hand hammer .State its
classification as per their uses
2. With a neat sketch explain various types of files. How are files classified
as per their uses?
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3. Describe the different types of punches used in fitting shops with a

neat sketch.
4. How are hacksaws specified? Draw a neat sketch of it.
5. Name different Marking and measuring tools used in fitting shops. And
give their brief description with a neat sketch.
6. What do you mean by M5x1.Draw a neat sketch with description of the
tool to generate it?
7. What was the material of the job you worked with?

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