METAL WORKING

FILLING AND FITTING

 SAFTIES IN METAL WORKING:
(USING HAND TOOLS)

1. Use the right tool for the job to be done.

2. Tools and hand tools should be clean and free of grease , oil, etc. before use.
3. Use sharp cutting tools. Dull tools cause accidents because you would apply
more force to use them.
4. Carry sharp tools with their points and cutting edges pointing downwards.
5. Heads of cold chisels and punches should not be cracked or mushroomed.
6. When using chisels, chip in the direction away from others.
7. When using a file, make sure it has a secure handle fitted. Otherwise you can
hurt your hand.
8. When you pass tools to others, give them the handle first.
9. Always report damaged tools to the tool store. They can repair them.
Damaged tools can cause injury.
10. Tools should always be wiped free of grease or dirt after use.
11. Return tools to the proper storage location after use.
 FILLING AND FITTING

A filling and fitting work can be subdivided into

following FOUR steps:

1. Drawing and Planning

2. Measuring and Laying-out
3. Cutting
4. Squaring and Smoothing (or
shaping)
 1. DRAWING AND PLANNING
MAKING A PRODUCT PLAN:
1. Before manufacturing a product, you should prepare a PRODUCT PLAN.
2. A product plan should have all the information needed for successful
construction of the product/ part.
3. A good PRODUCT PLAN includes:
a) A working drawing of the part
b) A bill of materials
c) List of steps, in proper sequence, for making the part.
WHAT IS A WORKING DRAWING?
1. A working drawing gives all information needed to make the part.
2. It must show the following kinds of information:-
a) Shape of the part
b) Size
c) Location and sizes of holes, if any
d) Kind of material
e) Kind of finish
 2. MEASURING AND LAYING-OUT
FOR LAYING OUT:
1. Colour metal for layout: To see the lines
on the surface easily, it is necessary to
colour it, normally with wet chalk. MARKING LINES WITH A SCRIBER

2. Use of Scriber: With the help of steel

rule, try square or bevel protractor, mark
lines using a scriber.
3. Use of Prick Punch: The lines may be
prick punched to make them last longer.
PRICK PUNCH
4. Use of Center Punch: Looks like a prick
punch, has a 90 deg point. Used to make
punch mark at centre of holes that are to
be drilled. CENTRE PUNCH

5. Laying out Circles and Arcs: Set the

divider to the size of the radius. Place
one leg in the prick punch mark, swing
other leg in a circle. DIVIDER
 2. MEASURING AND LAYING-OUT
MEASURING PROCESS:
1. Using Steel Rule: Put the edge STEEL RULE

of the rule against the work so

that the lines on the rule touch
the work.
2. Using Combination Set:
Includes:
a) Square Head
CENTER HEAD
b) Centre Head
BEVEL PROTRACTOR
c) Bevel Protractor
SQUARE HEAD
d) Steel Rule
e) Spirit level
3. Use of Micrometers:
a) Used for making fine
measurements
b) Can measure in thousandth of an
inch (1/1000”)
Using Combination Set:
 2. MEASURING AND LAYING-OUT

TRY SQUARE

INSIDE CALIPERS
OUT SIDE CALIPERS

HERMAPRODITE CALIPER
OR BENTLEG CALIPER SURFACE GAUGE
 3. CUTTING AND SHAPING
SAWING BY HAND: ADJUSTABLE FRAME

1. HACKSAW: It is the most common hand tool used for

cutting metal to size/ length. HANDLE
Many types of blades are available.
They have different sized teeth for cutting different kinds
of metal.
2. PARTS OF A HACKSAW: PRONGS

 Adjustable Frame TIGHTENING SCREWS

 Handle
 Blade
 Tightening Screw
 Prongs
3. BLADE SELECTION:
 It is made of thin, high grade steel that has been
hardened and tempered.
 Some have hardened teeth and soft back (flexible)
 Blade Material: molybdenum alloy steel, tungsten TEETH PER INCH (tpi)

alloy, mol. HSS, tungsten HSS

 HACK SAW / SAWING
NUMBER OF TEETH PER INCH (tpi):

Varies with type of blade and its use/ purpose:-

1. 14 tpi -- Soft steel, Al, brass, bronze, copper alloy (other
material ≥ 1” thick)
2. 18 tpi -- Machine steel, angle iron, tool steel, Al , Copper
alloys (other materials ¼” to 1” thickness)
3. 24 tpi -- For cutting materials 1/16” to ¼” thick, i.e. iron
pipes, metal conduits, light angle iron, etc.
4. 32 tpi -- For cutting material up to 1/16” thick. Cuts
sheet metal, thin wall tubing and thin angles &
channels.
 HACK SAW / SAWING

CUTTING STROKE:

1. To begin a cut, notch a starting place with a file. This makes

the starting saw strokes easier.
2. Begin with a backward stroke (no cutting)
3. Press down on the forward stroke & lift a little on the
return stroke
4. The blade cuts only on the forward stroke
5. First few strokes should be short ones, with little pressure
6. When cut is deep enough, increase stroke to full length.
 CUTTING AND SHAPING
CHISELS AND CHIPPING:
1. Chiseling is the art of shaping metal by
removing small pieces with a cold chisel
and hammer.
2. Cold chisels are used to cut metal that
has not been softened by heating
3. CHISELS are made of high grade steel in
a number of sizes and shapes
4. Cutting edges are hardened and
tempered because the cutting tool must
be harder than the material to be cut.
5. Cutting edge is a WEDGE which cuts into
the steel.

ATTENTION: ALWAYS WEAR SAFETY GLASSES

WHEN CHIPPING
 CUTTING AND SHAPING

TYPES OF CHISELS:

1. FLAT CHISEL: Used for general

cutting

2. CAPE CHISEL: Used to cut narrow

groves FLAT CHISEL

3. DIAMOND CHISEL: For V shape CAPE CHISEL

grooves

4. ROUND NOSE CHISEL: Used to ROUND CHISEL

chip round corners
 4. SQUARING AND SMOOTHING (OR SHAPING)
FILLING:
1. Metal can be shaped with files of many shapes and sizes

2. Normally, only limited shaping is done with a file

3. Usually, the file is used to:

a) Round corners
b) Bevel edges
c) Remove marks made by other tools
d) Work where only a small amount of metal is to be
removed/ cut away.
 SQUARING AND SMOOTHING (OR SHAPING)

USING A FILE:
1. File can cut all types of metal except hardened steel
2. Files should be used only on metal which is not as hard as the
file itself
3. Use a file with a handle
4. Use only a file with sharp teeth
5. Use both hands, one on handle, other on the tip
6. Cut by pressing down on the forward stroke, called the CUTTING
STROKE
7. Lift a little on the return stroke to prevent dulling of the file.
CLEANING A FILE:
1. File often gets clogged with chips.
2. Brush it with a wire brush to clean it to avoid scratches on the
work and improve its cutting action.
 TYPES OF FILES
1. FLAT FILE: Tapered in width and thickness. FLAT FILE

Used for general purpose work.

2. PILLAR FILE: Narrower and thicker than
hand file. Equal in width, tapered in
HALF ROUND
thickness. Used for narrow work, i.e., PILLAR

keyways, slots.
3. SQUARE FILE: Filing square corners, ROUND
enlarging square openings
4. ROUND FILE: Filing curved surfaces, holes
5. HALF ROUND FILE: Filing curved surfaces
6. HAND FILE: Finishing flat surfaces – has
one safe edge SQUARE FILE

7. THREE SQUARE FILE (TRIANGLE FILE):

Filing corners and angles less than 90° TRI ANGLE FILE

8. KNIFE FILE: Filling narrow slots, notches HAND FILE

and grooves.
KNIFE FILE
MACHINE TOOLS USED FOR CUTTING,
DRILLING, PUNCHING, DRILLING AND
BENDING
 DRILLING
DRILLING:
1. Using a drill to cut a hole is called drilling.
2. Need a drill and a tool to hold a drill:
 Hand drill
 Portable electrical drill
 Drill Press
3. Drilling feeds and speed (in/ rev, in/ min, rpm),
depends upon the diameter of hole and
material of drill and the job material.
 DRILLING

DRILL SIZES:
1. Drill size is known by its diameter.
2. Diameter can be indicated by:
a) Number gauge ( from 80 to 1) (0.0135” to 0.228”)
b) Letter size ( A to Z) ( .02340” to 0.413”)
c) Fraction size (1/64 “, 1/32”, ……. 1”)
3. Smallest size drill is drill No. 80
4. Largest size drill is drill No. 1”
5. Drills are usually purchased in sets.
 DRILL MATERIALS
1. Carbon & Low/Medium
Alloy Steels

2. High Speed Steels

3. Tungsten Carbide

4. Ceramics

5. Diamonds
TWIST DRILL NOMENCLATURE
 DRILLING MACHINES

Hand drill Radial Arm Drilling

Machine

Pillar Drill
 ABRASIVES

1. Abrading means to rub-off

2. Abrasive substances are very hard and tough
3. They are used to cut and abrade other
materials .
4. Common form of abrasives used in metal
working include:
 Abrasive cloth
 Grinding wheels
 Sharpening stones.
 SAWING MACHINES
Sawing machines is one of the most important machine tool in the
workshop.
Types:
CUTOFF MACHINES:
1. Reciprocating Saws
2. Horizontal Endless Band saw

BAND SAWS:
1. Vertical Band Saw
2. Horizontal Band Saw

CIRCULAR SAWS:
1. Abrasive discs

THE SIZE OF A RECIPROCATING SAW IS DETERMINED BY THE LARGEST PIECE OF SQUARE

MATERILA THAT IT CAN CUT. SIZES RANGE FROM 5 X 5 IN. TO 24 X 24 IN.
Reciprocating Saws
Reciprocating Saws
Horizontal Endless Band saw
Vertical Band Saw:
Abrasive saws
 SHEARING OPERATIONS
1. Shearing is the mechanical cutting of materials without the
formation of chips or the use of burning or melting.

2. When the two cutting blades are straight, the process is

called shearing.

3. Important processes under shearing process are:

a) Blanking : Punched out piece is work-piece
b) Piercing : Punched out pieces are scrap
PUNCHING/ PIERCING MACHINES
 BENDING

1. Bending is the PLASTIC DEFORMATION of metals

about a linear axis with little or no change in
surface area.

2. Multiple bends can be made simultaneously

3. When multiple bends are made with a single die,

the process is sometimes called FORMING.
BENDING
BENDING MACHINES
BENDING MACHINES
END OF TODAYS LECTURE