Politeknik Merlimau Melaka

Mechanical Engineering Department

Mechanical Workshop Practical JJ 103
Fitting Report

Name Matrix No. Class Lecturer Date of Submit

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: Chandran A/L Vasudevan : 14DKM11F1116 : DKM1C : Puan Gayathiri : 06-10-2011

Contents

Introduction And Objective Safety Tools And Materials Working Steps Problems encountered Conclusions References

Introduction

-Fitting refers to the mating of two mechanical components. Manufactured parts are very frequently required to mate with one another. They may be designed to slide freely against one another or they may be designed to bind together to form a single unit. The most common fit found in the machine shop is that of a shaft in a hole. There are three general categories of fits: 1) Clearance fits for when it may be desirable for the shaft to rotate or slide freely within the hole; this is usually referred to as a "sliding fit." 2) Interference fits for when it is desirable for the shaft to be securely held within the hole, this is usually referred to as an interference fit and 3) Transition fits for when it is desirable that the shaft to be held securely, yet not so securely that it cannot be disassembled, this is usually referred to as a Location or Transition fit. Within each category of fit there are several classes ranging from high precision and narrow tolerance (allowance) to lower precision and wider tolerance. The choice of fit is dictated first by the use and secondly by the manufacturability of the parts.

Objective

- Know basic workshop processes. - Read and interpret job drawing. - Identify, select and use various marking, measuring, holding, striking and cutting tools & equipments. - Operate, control different machines and equipments. - Inspect the job for specified dimensions - Produce jobs as per specified dimensions. - Adopt safety practices while working on various machines.

Safety Precautions

-Keep proper discipline in the shop

-Do not play with the tools because they are sharp -All files should be fitted with suitable handle at end of file. -When using Hacksaw, check its teeth should be sharp and forward position -When using chisel its direction should be kept away from other working persons. -When files are of forward cut, and then only apply the force in forward stroke not in backward and vice versa. -When using Hacksaw check its blade with must be fitted in pins properly. - Clean up oil and grease or other liquid which spills on the flour otherwise they may be a cause of accident. -Do not wear any neck tie, jewelers, rings, and watches during in the working in shops.

Tools & Materials

Fitting Tools:-

The tools used in fitting shop may be classified into following groups.

-Measuring -Holding -Cutting -Striking -Drilling -Marking

Materials: Mild Steel (170mm x 50mm)

Measuring Tools

Steel Ruler

It is a cliff straight steel strip having all faces machined true. One of flat face graduation mark and In inches and also in centimeters. It is used to set out dimensions.

Try Square It consists of steel blade fixed at right angle to the edge of cast iron stock. It is used for checking of right angles, the squareness and surface and also draws line at right angle.

Scriber It is made of steel and one end is sharp pointed and other end is similar but bent. This tool is used for scribing line on work piece.

Centre Punch A punch is primarily a marking tool used in bench work and known as center punch, this tool is Used for making center for turning on lathe machine as well as for centering of holes for drilling.

Holding Tools

Bench Vice The bench vice is very essential tool in every shop but commonly used in fitting shop. It is used for holding and attaching the work to the bench. It has two jaws, one is fixed and other is movable. Cutting Tools File The file is hardening piece of high grade steel or high carbon steel with slating saws. It is used for cut smooth or fit metal parts. It is used to cut the metal expected harden steel and it is used in forward stroke. Types of Files

Flat File

It has double cut on both sides and single on both edges. It is mostly used for general work and filing flat surfaces. A large amount of metal can be removed with this file, and they don't produce smooth surfaces.

Square File It is double cut file on all sides, and used for enlarging square holes and filing of slats and key ways.

Triangular File Its section is triangular and faces are double cut and edges are single cut. Its each side on 60 degrees. It is used for filing internal angles, shoulders or corners and for sharpening wood working saws.

Round File Round file is also usually double cut. It is used for enlarging holes, slots, and concave and for enlarging the holes.

Hack Saw The hack saw is chief cutting tool used for cutting rods, bars, pipes into desired length. It consist of metal frame the blades which fits over two pins. The wing nut of the frame is used for tensioning the blade. The blades are made of high carbon or high speed steel. The most useful blade for handwork is 30 cm long and 12-24 mm width (24 teeth). Striking Tools All types of hammers are called striking tools. It consists of head face, peen and a handle. Its head is made of plane carbon steel and have both end hardened and tapered. Its handle is made of wood. Types of Hammer

Ball Peen Hammer The ball peen hammers peen is like as a ball, therefore it is called ball peen hammer. It is used for Riveting.

Cross Peen Hammer The cross peen hammer is used hammering into shoulders or hammering inside curves for bending or stretching metals. Drilling

is a cutting process that uses a drill bit to cut or enlarge a hole in solid materials. Marking tools

Vernier height gauge A height gauge is a measuring device used either for determining the height of something, or for repetitious marking of items to be worked on.

Angle plates is a work holding device used as a fixture in metalworking

Procedure
Step 1 Object: Cut and filling to prepare two work pieces for marking Material: Mild steel of size 170 x 50 Tools and Equipments: Bench Vice, Hack Saw,Files,Vernier Height Gauge, Angle Plates

Procedure:
i)

First we mark the work piece to cut into two pieces. (75 x 50)
a) Stand the work piece on angle plate . b) Mark the work pieces according to given measurement by

vernier height gauge.

c) Draw lines on marking using scriber

ii)
iii)

Take the work pieces and adjust in the bench vice. Then cut the given mild steel to two pieces using a hack saw. Now we having to equal pieces of work pieces.(70 x 50) Start filing horizontal side with flat file then check the flat surface of the given piece with try square, then starts the filing the vertical side. Check flat surface with try-square. If both work pieces can stand without support, then its completed.

iv)
v)

vi) vii)

Note: All dimensions are in millimeters (mm) Step 2 (Part A) Object: Cut and filling the first piece of work pieces which cutter (Part A) according to the measurement and shape given Material: Part A work piece Tools and Equipments: Bench Vice, Hack Saw, Files, Vernier Height Gauge, Angle Plates

Procedure:
i)

First we mark the work piece according to the measurement and shape given.
a) Stand the work piece on angle plate . b) Mark the work pieces according to given measurement by

vernier height gauge.

c) Draw lines on marking using scriber

i) ii)
iii)

Take the work pieces and adjust in the bench vice. Cut the work piece according to the shape and measurement needed. Start filling the work piece on both its horizontal and vertical side until get flat surface and measurement needed. Check with try-square. If get the needed measurement then its completed

iv)

Note: All dimensions are in millimeters (mm)

Step 3 (Part B) Object: Cut, filling and drilling the second piece of work pieces which cutter (Part B) according to the measurement and shape given Material: Part B work piece Tools and Equipments: Bench Vice, Hack Saw, Files, Vernier Height Gauge, Angle Plates, Drill Machine, Hammers and Centre Punch.

Procedure:
i)

First we mark the work piece according to the measurement and shape given.
a) Stand the work piece on angle plate . b) Mark the work pieces according to given measurement by

vernier height gauge.

c) Draw diagonals on marking using scriber i) ii)

By using hammer and center punch mark the center by diagonals Hold the work piece on drill machine tietly and start drilling on the center marked.(put oil while drilling to avoid drill bit heated and affect the process). Take the work pieces and adjust in the bench vice. Cut the work piece according to the shape and measurement needed. Start filling the work piece on both its horizontal and vertical side until get flat surface and measurement needed. Check with try-square. Try to fit both work pieces Part A and Part B together. If fits then its completed

i) ii) iii) iv)

v)

Note: All dimensions are in millimeters (mm)

Problems Encountered

Cutting on the work pieces not straight Solution: hold hack saw on proper way. Tilt the hack saw 45 from the work piece when cutting.

Lack of accuracy on measurement Solution: Make sure the surface of work piece flat when marking using angle plate and vernier height gauge.non flat surface will affect the measurement and also the shape. Work pieces not in required shape or not fit each other. Solution: Make sure the surface of work piece flat when marking using angle plate and vernier height gauge.non flat surface will affect the measurement and also the shape.

Conclusion
On the end of this Fitting project I had learn how to use equipment and machinery such as files, center punch, vernier height gauge and drilling machine. I also learned how to conduct a project and finish its report. I also learned the importance of fitting process in engineering field.

References

www.google.com/image

www.yahoo.com/image www.en.wikipedia/fitting process.com

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