B.

Tech/Diploma in ME/CE/EE/RA/CSE and I/II Semester

Engineering Workshop Practices
Academic Session: 2024-2025 ODD/EVEN

Workshop Manual
(FITTING)

Table of Contents

Lab Name of the Experiment/Activity/Exercise Page

Exercise/Activity Number(s)
No.
1 To make a Mushroom fit as per the drawing of given dimensions 2-5
from a Mild Steel plate.
2 Introduction and Theory 6-14

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Engineering Workshop Practices
Academic Session: 2024-2025 ODD/EVEN

1. Job Name: To make a Mushroom fit as per the drawing of given dimensions from a Mild
Steel plate.

2. Aim: To study different types of operations and hand tools used in fitting shop.

3. Learning outcome:
a. Learn how to use various measuring tools such as calipers, micrometers, and gauges
to ensure accurate measurements for components.
b. Develop skills in fitting and assembling different components to create functional
mechanical systems.

4. Prerequisites: NA

5. Tools/Equipments:
● Fitter’s Bench vice
● Steel rule
● Inside and outside calliper
● Surface plate
● Scriber and surface gauge
● Punches & Hammer
● Drill
● Tap and tap wrench
● Try-square
● Hacksaw
● Files

6. JOB DIAGRAM:

Figure 1: Schematic diagram of specified job (All dimensions are in mm)

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7. PROCEDURE:
1. The given mild steel flat piece is checked for given dimensions.
2. One edge of given is filled to straightness with rough and smooth files and checked with try
square.
3. An adjacent is also filled such that is square to first edge and checked with try square.
4. Wet chalk is applied on one side of the flat and dried for marking.
5. Lines are marked according to given figure, using odd leg calliper, steel rule and divider.
6. Using the dot punch and hammer make the marked lines prominent.
7. The excess materials removed from according to the marking by using saw, drill and filling.
8. After that, tapping is been done in the required drilled hole.
8. Finally buts are removed by the filling on the surface of the fitted job.

8. SEQUENCE OF OPERATIONS:

Measuring Checking Squaring Filing Layout / Marking

Filling Chiselling Drilling Sawing Punching

Tapping Finishing Letter and number Punching.

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Academic Session: 2024-2025 ODD/EVEN

JOB SHEET

Sl. Sketch Operation Hand Tools Measuring Signature

No Name Tools

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Engineering Workshop Practices
Academic Session: 2024-2025 ODD/EVEN

9. PRECAUTIONS:

a. The perpendicular of face ends edges is checked perfectly by using try square.
b. Finishing is given by using only with smooth files.
c. Marking is done without parallax error.
d. Machines must be shut off during cleaning, repairing, or oiling operations.
e. Never indulge in horseplay in the shop areas.
f. Do not wear ties, loose clothing, jewellery, gloves, etc. around moving or rotating
machinery.
g. Shoes must be worn in any shop area. No one wearing sandals will be allowed to
enter any shop area.
h. Do not operate any item of equipment unless you are familiar with its operation and
have been authorized to operate it.
i. No work may be performed using power tools unless at least two people are in the
shop area and can see each other.

10. Observations:
The following observations are obtained are given below,
1.
2.
3.

11. Answer the following:

1) Define the term fitting.

2) What is fit? Define various types of fit.
3) Name and describe different types of measuring and marking tools used in the fitting
shop with a suitable diagram.
4) Explain different operations performed in the fitting shop.
5) How do you specify a File? Name of a few files used in the fitting shop with net
sketch.

12. Assessments:
Workshop Copy: 20 Marks
Performance: 10 Marks
Viva-Voce: 10 Marks

13. Suggested readings:

i. Hazra Choudhury, S. K., Roy, N. (2016), Elements of Workshop Technology, (15th Edition),
Media Promoters & Publishers PVT. LTD.

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Engineering Workshop Practices
Academic Session: 2024-2025 ODD/EVEN

DESCRIPTION ON FITTING SHOP & TOOLS USED

INTRODUCTION:

The term fitting, is related to the assembly of parts, after bringing the dimension or shape to
the required size or form, in order to secure the necessary fit. The operations required for the same
are usually carried out on a workbench, hence the term bench work is also added with the name fitting.
The bench work and fitting together play an important role in engineering. Although in today's
industries, most of the work is done by automatic machines which produce the jobs with good
accuracy still the job requires some hand operations for precision which can be done by fitting
operations. The person working in the fitting shop is called the fitter.

FITTING TOOLS:

Fitting shop tools are classified as below:

1. Work Holding Devices

2. Measuring Tools
3. Marking Tools
4. Cutting Tools
5. Striking Tools

1. WORK HOLDING DEVICES:

1.1 FILTER’S AND BENCH VICE

It is firmly fixed to the bench with the help of nuts and bolts. It consists of a cast Iron body
and cast Iron jaws. Two jaw plates are fitted on both the jaws. When the vice handle is turned in a
clockwise direction the moving jaw forces the work against the fixed jaw. The holding surface of the

Figure 1.1: 1 Filter’s and bench vice

jaw plates is knurled in order to increase the gipping. Jaw plates are made up of carbon steel and are
wear resistant. One jaw is fixed to the body and the second slides on a square threaded screw with the
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help of a handle. The jaws are opened up to required length, job is placed in the two jaws
and is fully tightened with the help of handle. Handle is used to move the movable jaw.

2. MEASURING TOOLS
2.1. Steel Rule
These are made up of stainless steel and are available in many sizes ranging from 1/2 ft. to 2 ft. These
are marked in inches or millimetres. All the faces are machined true. The edges of steel rule should
be protected from rough handling.

Figure 2.1: Steel rule

2.2 Callipers
These are generally used to measure the inside or outside diameters. Different types are
● Outside Calliper: It is used to measure the outside dimensions.
● Inside Calliper: It is used to measure the inside dimensions.
● Spring Calliper: Spring is provided to apply the pressure and lock nut is provided to lock any
desired position.
● Hermaphrodite, Jenny or Odd leg Calliper: One leg is bent at the tip inwardly and the other
has a Straight pointed end. It is used to scribe lines parallel to the straight edges.

Figure 2.2: Different types of calliper

3. MARKING TOOLS:
3.1. Surface Plate

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It is used for testing the flatness, trueness of the surfaces. It is made up of cast iron or
graphite. Its upper face is planned to form a very smooth surface. It is also used in scribing work.
While not in use, it should be covered with a wooden cover.

Figure 3.1: Surface plate

3.2 V-block with clamp

The 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 marking of measurements or for measuring operations.
Material: C.I or hardened steel. Size: 50 to 150 mm.

Figure 3.2: V-block with mounted clamp

3.3. Angle Plate

It is made up of cast iron in different sizes; it has two planed surfaces at right angles to each other and
has various slots in each surface to hold the work by means of bolts and clamps. Never do hammering
on the angle plate to fasten (lighten) the nuts and bolts.

Figure 3.3: Pictorial Angle plate

3.4. Scriber and Surface Gauge

It consists of a cast iron bass on the centre of which a steel rod is fixed vertically. Scriber is made up
of high carbon steel and is hardened from the front edge. It is used for locating the centres of round
bars or for marking of the lines.
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Figure 3.4: Scriber and surface gauge

3.5. Punches
Punches are used for marking purposes. Dot punches are used for marking dotted line and centre
punch is used to mark the centre of hole before drilling. Punches are made up of high carbon steel or
high-speed steels. In dot punch, angle of the punching end is 600 while in centre punch, angle of
punching end is 900.

Figure 3.5: Different types of punches

3.6. Try Square

It consists of a blade made up of steel, which is attached to a base at 900. The base is made up of cast
iron or steel. It is also used to mark the right angles and measuring straightness of surfaces.

Figure 3.6: Front view of try square

Method of Marking
Marking means setting out dimensions with the help of a working drawing or directly transferring
them from a similar part. The procedure of marking are as follows:

1. The surface to be marked is coated with the paste of chalk or red lead and allowed to dry.
2. Then the work is held in a holding device depending upon shape and size. If it is flat, use
surface plate, if it is round use V block and clamp, else use angle plate etc.
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Academic Session: 2024-2025 ODD/EVEN
3. Lines in horizontal direction are scribed by means of a surface gauge. Lines at right
angles can be drawn by turning the work through 900 and then using the scriber. If true surface
is available, try square can also be used.
4. The centre on the end of a round bar can be located by using an odd leg calliper, surface gauge
etc.
5. The circles and arcs on a flat surface are marked by means of a divider.
6. After the scribing work is over, indentations on the surface are made using dot punch and
hammer.

4. CUTTING TOOLS
4.1. Hacksaw
Hacksaw is used for cutting of rods, bars, pipes, and flats etc. It consists of a frame, which is made
from mild steel. The blade is placed inside the frame and is tightened with the help of a flange nut.
The teeth of the blades are generally forward cut so in the case, pressure is applied in the forward
direction only.

Figure 4.1: Hand hacksaw in fixed and adjustable frame

4.2. Files
Files are multi points cutting tools. It is used to remove the material by rubbing it on the metals. Files
are available in a number of sizes, shapes and degree of coarseness.

Figure 4.2: (a) Single cut and (b) Double cut file

4.2.1. Classification of files

I. On the basis of length: 4”, 6”, 8” and 12”
II. On the basis of grade
a. Rough: Rough and bastard files are the big cut files. When the material removal
is more, these files are used. These files have bigger cut but the surface produced
is rough.
b. Second cut: It has a degree of finish in between bastard and smooth file.
c. Smooth file: has smaller teeth and is used for smaller cuts.
d. Dead smooth: has smaller teeth and is used for smaller cuts.
III. On the basis of the number of cuts
a. Single cut files: Teeth are cut in parallel rows at an angle of 600 to the face.

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b. Double cut files: Another row of teeth is added in the opposite direction. Material
removed is more in the case of double cut files.
c. Rasp files: It is a coarse form of file used for coarsely shaping wood or other material. It consists
of a generally tapered rectangular, round, or half-round sectioned bar of case-hardened steel
with distinct, individually cut teeth.
IV. On the basis of shape and size
The length of the files varies from 4' to 14'. The various shapes of cross-section are available i.e.,
hand file, flat file, triangular, round; square, half round, knife-edge, pillar, needle and mill file.
a. Flat file: This file has parallel edges for about two-thirds of the length and then it tapers. The faces
are double cut while the edges are single cut.
b. Hand file: for a hand file the width is constant throughout, but the thickness tapers as given in flat
file. Both faces are double cut and one edge is single cut. The remaining edge is kept uncut in order
to use for filing a right-angled corner on one side only.
c. Square file: It has a square cross-section. It is parallel for two-thirds of its length and then tapers
towards the tip. It is double cut on all sides. It is used for filing square corners and slots.
d. Triangular file: It has a width either parallel throughout or up to the middle and then tapered
towards the tip. It has a triangular (equilateral) section. The three faces of the files are double cut and
the edges are in single cut. It is used for filing square shoulders or comers and for sharpening wood
working saws.
e. Round file: It has a round cross-section. It carries single cut teeth all around its surface. It is
normally made tapered towards the tip and is frequently known as a rat-tail file. Parallel round files
having the same diameter throughout the length are also available. The round files are used for
opening out holes, producing round comers, round-ended slots etc.
f. Half-round file: Its cross-section is not a true half-circle but is only about one-third of a circle. The
width of the file is either parallel throughout or up to the middle and then tapered towards the tip. The
flat side of this file is always a double cut and curved side has a single cut. It is used for filing curved
surfaces.
g. Knife edge file: It has a width tapered like a knife blade and it is also tapered towards the tip. It
carries double cut teeth on the two broad faces and single cut teeth on the edge. It is used for finishing
sharp corners of grooves and slots
h. Diamond file: Its cross-section is like a diamond. It is used for special work.
i. Needle file: These are thin small files having a parallel tang and a thin, narrow and pointed blade
made in different shapes of its cross-section to suit the particular need of the work. These are available
in sizes from 100 mm to 200 mm of various shapes and cuts. These files are used for filing very thin
and delicate work.

Figure 4.3: Various profile of files

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Figure 4.4: Components of files

5. Methods of filing
The following are the two commonly used methods of filing:
1. Straight Filing.
2. Cross Filing.
3. Draw Filing.
5.1. Straight Filing: The first and most basic filing technique is called straight-filing, and involves
pushing the file lengthwise across the work, making contact only on the forward stroke. Straight-
filing is typically used to rapidly remove material

Figure 5.1: Straight filing operation

5.2. Cross -filing.
This method is used for efficient removal of maximum amount of metal in the shortest possible time.
It may be noted that the file must remain horizontal throughout the stroke (long, slow and steady)
with pressure only applied on the forward motion.

Figure 5.2: Cross- filing operation

5.3. Draw filing.

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This method is used to remove file marks and for finishing operations. Here, the file is
gripped as close to the work as possible between two hands. In this filing method, a fine cut file with
a flat face should be used.

Figure 5.3: Draw filing operation

6. FILE CARD
It is a device fashioned like a wire brush used to clean dirt and chips from the teeth of a file. When
particles of metal clog in to the teeth of the file, is known as pinned. It is a condition that causes
scratching of the surface of the work. Therefore, cleaning is required with the help of a file card or
by dislodging the material stuck in between the teeth by means of a piece of soft iron, copper, brass,
tin plate and so on materials which are sharpened at the end. Hardened steel should never be used for
this purpose.
7. STRIKING TOOLS
A hammer is a tool that, usually featuring a head fixed to a handle delivers a blow to an object to
break it apart, drive it into another, or beat it into a desired shape. There is different type of hammer
such as
● Ball-peen hammer
● Boiler scaling hammer
● Brass hammer
8. TWIST DRILL
Twist drills (also commonly referred to as twist bits) are the most widely used of all drill bit types;
they will cut anything from wood and plastic to steel and concrete. They are most frequently used for
metal cutting, so they are generally made from M2 high-speed steel

Figure 8.1: Twist drill and its different parts

9. FIT
Engineering fits are generally used as part of geometric dimensioning and tolerancing when a part or
assembly is designed. In engineering terms, the "fit" is the clearance between two mating parts, and
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the size of this clearance determines whether the parts can move independently from each
other, or can be temporarily / permanently joined.

9.1 TYPES OF FIT:

The three types of fit are:
▪ Clearance: The hole is larger than the shaft, enabling the two parts to slide and rotate when
assembled.
▪ Transition: The hole is fractionally smaller than the shaft and mild force is required for
assembling/disassembling.
▪ Interference: The hole is smaller than the shaft and high force and/or heat is required for
assembling/disassembling.

**The assignments of the Workshop must contain the Top Sheet and the answers to the
questions provided here.

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