Basic Manufacturing Systems

[ME1083]
School Of Mechanical Engineering
KIIT Deemed to be University
Introduction
• What is Fitting?
• Fitting is the process of assembling various parts manufactured in the machine
shop
• Working on components with hand tools and instruments, mostly on work
benches is generally referred to as 'Fitting work’.
• The hand operations in fitting shop include marking, filing, sawing, scraping,
drilling, tapping, grinding, etc., using hand tools or power operated portable
tools

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Fitting Section Experiment
• Aim of experiment: To prepare a Square base paper weight
• Raw Material Required: Mild Steel flat (50 x 50 x 6 mm), Mild Steel
round bar (40 mm x ∅ 6 mm).
• Tools required:
• Holding Tools: Bench vice
• Marking Tools: Scriber, Dot punch
• Measuring Tools: Steel rule, Vernier Caliper, Try square, measuring plate
• Cutting Tools: Hacksaw, 5mm twist drill
• Finishing Tools: Flat file, Round file
• Striking Tools: Ball-Peen hammer, Mallet

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Fitting Tools

Dot punch

Scriber

Bench vice

Steel Rule Vernier Caliper

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Fitting Tools

Hacksaw
Twist Drill
Try square

Round file

Flat file Ball-peen hammer

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Operations in Fitting Section
• Operations involved are -
• Measuring and marking
• Holding and Cutting
• Filing
• Center marking
• Drilling
• Striking

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Job Layout

All Dimensions are in mm

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Procedure
• Cut the raw material of appropriate size i.e. 50 x 50 x 6 mm sand using
a flat file and try square, make all the adjacent sides perpendicular to
each other
• Using flat file, file the both side surfaces to make them flat and smooth
• Apply a thin coat of chalk powder on one surface of the workpiece and
let it dry
• Join two opposite vertex to draw two diagonals by using steel rule and
scriber
• Punch the intersection point of two diagonals using a dot punch and
ball peen hammer; this point will be the center point for making the
hole by drilling operation

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Procedure
• Drill a hole of 5 mm diameter using the drilling machine and the drill
bit
• Then prepare the round bar by filing operation; remove any sharp
edges and smooth the surface using a file
• One end of this round bar should be made slightly taper for facilitating
the striking operation
• Strike the round bar into the base part using the ball peen hammer
• Check all the dimensions using a Vernier caliper to ensure the correct
dimensions of the square base paper weight
• Submit the part to the class teacher

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Safety Precautions
• Safety precautions to be followed in fitting section
• Always wear an apron and a safety glass to be safe from any dust particles
• Wearing a hard-sole shoe is must for the safe movement inside the lab
• Right posture should be maintained during filing or cutting operation to avoid
any injuries to your hand
• Position the work piece area such that the cut to be made is close to the vice.
This practice prevents springing, saw breakage and personal injury.
• Apply force only on the forward (cutting) stroke, relieve the force on the
return stroke
• You need to be more attentive during drilling operation to avoid any accident
• Enough care must be taken while handling the workpiece and tools; the sharp
edges may injure your hand

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Safety Precautions
• Right and Wrong working in Fitting shop
• With left foot set forward the whole of the body is in action and the
filing or cutting stroke with pressure is done without much strain to
hands or legs.
• In the second case with body movement the arm would tire soon

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Introduction

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Measuring and Marking Operations
• Accurate marking is the first step; and the methods and instruments
used are common in all fitting works.
• Measurements are taken either from a finished edge or from a center
line.
• Measuring and testing are continuous processes throughout the
manufacturing, whether working with hand tools or machines
• Tools used are:
• Steel rule
• Scriber
• Try square

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Measuring
and
Marking
Operations

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Holding and Cutting Operations
• After the marking operation, the workpiece will be fixed in a
bench vice and cut to the required size by a hacksaw
• Tools used
• Bench Vice:
• Hacksaw
• The bench vice is a device commonly used for
holding the work pieces.
• When the vice handle is turned in a clockwise
direction the moving jaw forces the work
against the fixed jaw

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 Holding
and
Cutting
Operations

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Filing Operation
• Filing Operation: Filing is one of the methods of removing small
amounts of material from the surface of a metal part.
• A file is a hardened steel tool, having slant parallel rows of cutting edges
or teeth on its surfaces. On the faces the teeth are usually diagonal to the
edge.
• Tools sed:
• Flat File
• Bench Vice
• Try Square

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Filing Operation
• Types of File:
• Hand file
• Flat file
• Square file
• Triangular file
• Round file
• Half-round file
• Swiss or needle file

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Filing Operation
• Types of Filing:
• Through filing: The file is held flat against the surface it is to cut / smooth.
The file is then pushed forward, and it cuts on the forward stroke. It is then
lifted away from the metal and returned to the starting point for the next
push forward.

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Filing Operation
• Types of Filing:
• If the surface produced by through filing is not good enough - the next stage
is ‘Draw filing’. The file is held in both hands by the blade and pushed
forwards and backwards along the material. This will further smooth the
material.

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Filing Operation
• With filing diagonally across the work, smooth finish is obtained. Note that
the file moves in the direction of the length of the file as shown. In the
second case cut of the file teeth are produced on the work.
• Keep the work as low in the vise as possible. Work too high means lack of
rigidity and too much vibration

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 Filing
Operation

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Center Marking
• Why Center Marking?
• It is required for the purpose of drilling operation
• Center mark helps in positioning the drill bit
• What are the tools required?
• Chalk
• Steel rule and Scriber
• Center punch
• Ball-peen hammer
• Anvil

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Center
Marking

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Drilling Operation
• Drilling Operation
• Drilling is a cutting process that uses a drill bit to cut a hole of circular cross-
section in solid materials.
• A bench drilling machine is generally fixed on the work bench
• The main parts of this machine are:
Base, column, portable, spindle, head, and drive mechanism.

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Drilling Operation
• Tool used:
• Drill bit
• The drill bit is usually a rotary cutting tool, often multi-point. The bit is
pressed against the work-piece and rotated at rates from hundreds to thousands
of revolutions per minute
• Drill bits are used to remove material to create holes, almost always of circular
cross-section. Drill bits come in many sizes and shapes and can create different
kinds of holes in many different materials.

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Drilling Operation
• Procedure
• Layout and mark the centers of each hole, with a center punch.
• Select proper size drill bit and fix it in the chuck properly.
• Clamp the work in a vice or to the bench.
• With the power-off position the drill point at the center punch mark.
Make sure that the tool is square with the surface.
• Hold the drill with one hand and steady it with the other. Put-on the
power and apply pressure steadily.
• Release the pressure slightly, when the point of the drill pierces the
lower surface of the metal.
• Remove the tool from the hole and put it off.

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 Drilling
Operation

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Shaft Preparation
• Round bar [Shaft] preparation
• Cut the round bar of required size by using a hacksaw
• Filing the round bar to remove rust from the surface to make it shine and
smooth
• Make one side of the round bar slightly taper as it will help to strike the bar
easily into the bore of the square base
• Tools used are -
• Hack saw
• Steel rule and scriber
• Flat file

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Striking Operation
• The prepared round bar will be inserted to the bore by striking it by
the help of a hammer
• The operation will be carried out by placing the square base over an
anvil
• Tools used are -
• Hammer
• Anvil

Anvil
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 Striking
Operation
& the final
Job

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Concluding Remarks
• Summarize the learning points from this section

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Task for Students
• Write the steps to be followed for preparing a round-base paper
weight?
• Highlight the operations involved
• Tools used for each operation
• Draw the diagram of the job
• [Hint must be given to the students for how to prepare a round
base from the given flat MS piece]

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Task for Students
• Round-based paper weight

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Quiz
• Faculties can give some instructions regarding quiz test
• The test should be conducted by MCQ test comprising of 10 questions
• Example:
• Which of the following tool can be used to check the perpendicularity of two
adjacent sides of a workpiece
a) Steel Rule
b) Try Square
c) Snip
d) Scriber

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Assessment

Class Work [Write up of task] 10*4 = 40

- To be conducted after end of each section
Quiz 5*4 = 20
- To be conducted after end of each section
Daily Performance 5*4 = 20

End Semester Test 20

- To be conducted at end of semester
Total 100

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Important Instructions for BMS Faculties
• In the first class [1st week only], faculties must give a brief introduction of
BMS Lab
• What are the different sections
• What are the different machines we have in the BMS Lab
• What the students will learn by end of this Lab class
• Assessment procedure of BMS class
• Some contents can be added to the current ppt
• If the faculty feels some more material can be added to this current PPT
• All the faculties are suggested to go through the PPT files to get acquainted with the
content
• Any discrepancy in the content, kindly inform to the class coordinator [especially in
the videos]

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Important Instructions for BMS Faculties
• 3 classes can be considered for completing one section
• Out of which the first two classes can be reserved for completion of
the lecture-video PPT
• The last one can be used for assessment of that section [Task write-up
and Quiz test]
• It is being suggested to all faculties to use Google Classroom for the
managing the BMS classes
• Collection of Task write up [3rd class of each section]
• Conducting Quiz [3rd class of each section]
• Evaluation – Let the students know their marks after one week of completion

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