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Producing Components Using Hand Fitting Techniques

QPEO2/005N

Objectives

Understand the principles of hand fitting Identify common hand tools and their uses Learn about measurement and marking out techniques

Expectation

In these lessons, you will learn about hand tools, measurement techniques, and safety requirements as outlined in the unit summary. During the practical session, you'll have the opportunity to apply what you've learned in the classroom by performing hands-on tasks. You'll practice basic operations such as filing, sawing, and drilling, allowing you to develop your skills in a workshop environment under supervision

Workshop task

Quiz

Measurement and Marking Out

Hand Tools for Fitting

Overview of hand fitting in engineering

Objectives

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Overview

Hand fitting is a fundamental skill in engineering that involves using various hand tools and techniques to shape, form, and finish components. It requires precision, attention to detail, and a good understanding of different materials and tools.

Info

  • Key aspects of hand fitting in engineering include:
  • Planning: Engineers must plan the sequence of operations for fitting tasks, considering the most efficient and effective approach.
  • Tool selection: Choosing appropriate tools like files, hacksaws, chisels, drills, and measuring instruments based on the specific operations and required accuracy.
  • Marking out: Accurately marking materials to guide the fitting process.
  • Material removal: Using hand tools and sometimes power tools to remove material and create desired shapes and features.
  • Measurement and quality control: Regularly checking work against specifications using appropriate measuring equipment.
  • Finishing: Performing final operations like threading, scraping, lapping, or off-hand grinding to achieve required surface finish and precision.

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Workshop task

Quiz

Measurement and Marking Out

Hand Tools for Fitting

Overview of hand fitting in engineering

Objectives

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Wire brush

Punches

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FIles

Flat,Round, Half Round

Chisels

Hammer

Hacksaw

Workshop task

Quiz

Measurement and Marking Out

Hand Tools for Fitting

Overview of hand fitting in engineering

Objectives

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Drilling

Hacksawing

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Filing

Basic Hand Fitting Operations

  • Objectives:
  • Practice using basic hand tools safely
  • Perform simple fitting operations
  • Apply measurement and marking out skills

Workshop task

Quiz

Measurement and Marking Out

Hand Tools for Fitting

Overview of hand fitting in engineering

Objectives

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When using files, follow these key techniques:

  • The material you're working with
  • The amount of material you need to remove
  • The desired finish of the workpiece
  • These filing techniques are crucial for producing components with features such as flat, square, parallel and angular faces, as well as radii and curved profiles. Mastering these skills will help you achieve the accuracy and quality required in hand fitting operations.

When using files, follow these key techniques:

  • Maintain a correct grip and body position for optimal control and efficiency.
  • Apply even pressure throughout long, steady strokes to ensure uniform material removal.
  • Keep the file level with the work surface, unless intentionally tilting for specific purposes.
  • Clean the file regularly with a file card to prevent clogging, which can affect performance and surface finish.

Techniques

In engineering, half-round files are used for: Filing curved surfaces and grooves Smoothing fillets and internal radii Working on both flat and concave surfaces

Half Round Files

In engineering, round files are used for: Enlarging drilled holes Smoothing the inside of curved surfaces Creating concave radii

Round Files

IIn engineering, flat files are used for: Smoothing large flat surfaces Squaring edges of workpieces Removing burrs after sawing or drilling

Flat Files

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Back

Remember these factors

Workshop task

Quiz

Measurement and Marking Out

Hand Tools for Fitting

Overview of hand fitting in engineering

Objectives

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These blades combine a hard cutting edge with a flexible backing, allowing for durability and versatility in cutting a wide range of materials, including harder metals.

These blades are designed to bend without breaking, making them ideal for cutting irregular shapes or curves in softer materials.

Flexible Blades

These blades are made from a single piece of hardened steel, making them suitable for cutting softer materials like plastic and thin metals.

All Hard Blades

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Bi-Metal Blades

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Workshop task

Quiz

Measurement and Marking Out

Hand Tools for Fitting

Overview of hand fitting in engineering

Objectives

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Next, you will discuss the significance of teeth per inch (TPI) on the blades. Blades with lower TPI (e.g., 14 TPI) are typically used for cutting thicker materials, while those with higher TPI (e.g., 32 TPI) are better suited for thinner materials, providing a smoother finish. You will also learn how to select the appropriate blade based on: The type of material you are cutting (e.g., metal, plastic). The thickness of the workpiece. The desired finish of the cut. Throughout this lesson, you will practice proper hacksaw techniques, including how to securely install the blade, apply the correct pressure during cutting, and maintain the hacksaw for optimal performance. By the end of the lesson, you should have a clear understanding of how to choose and use hacksaw blades effectively in various engineering tasks.

All Hard Blades

TPI

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Workshop task

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Measurement and Marking Out

Hand Tools for Fitting

Overview of hand fitting in engineering

Objectives

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Tools used for marking out

Tools used for measuring

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Measuring and marking out are crucial steps in hand fitting processes. They ensure accuracy and precision in the production of components. Here are the key points related to measuring and marking out: Importance: Accurate measuring and marking out are essential for producing components that meet specified dimensions and tolerances.

Safety considerations

Features to be marked out

Quality control

Techniques

Workshop task

Quiz

Measurement and Marking Out

Hand Tools for Fitting

Overview of hand fitting in engineering

Objectives

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Instructions

Workshop task

Quiz

Measurement and Marking Out

Hand Tools for Fitting

Overview of hand fitting in engineering

Objectives

Home

Job 1

Basic Filing and Marking Out.

  • Operations Covered:
  • Mark out a rectangular profile on a mild steel bar (Criteria S2.1, S3.1).
  • Use direct marking techniques with scribers and rulers (Criteria S3.1, S4.1, S4.2).
  • File the material to achieve flat datum faces and square profiles (Criteria S6.1, S7.1, S7.4).
  • Tools and Equipment:
  • Scriber, ruler, engineer’s square, files.
  • Vernier caliper for measurement (Criteria S10.3).
  • Assessment Criteria:
  • Ensure faces are flat and square within a tolerance of ±0.25mm (Criteria S11.2, S11.4).
  • Verify the finish with comparison plates (Criteria S11.8).

Objective: To mark out and file a rectangular block of mild steel.

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Job 2

Tools and equipment

Workshop task

Quiz

Measurement and Marking Out

Hand Tools for Fitting

Overview of hand fitting in engineering

Objectives

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Job 1

Basic Filing and Marking Out.

Instructions

  • Mark Out the Rectangle: Use a scriber and a steel ruler to mark out a rectangular profile on a piece of mild steel bar.
  • Filing: Use a file to flatten the marked area, ensuring the faces are flat and square.
  • Measurement: Use a Vernier caliper to measure the dimensions and check the squareness and flatness.
  • Assessment Criteria:
The faces should be flat and square within a tolerance of ±0.25mm.

Instructions

Workshop task

Quiz

Measurement and Marking Out

Hand Tools for Fitting

Overview of hand fitting in engineering

Objectives

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Job 2

Drilling and Threading

  • Operations Covered:
  • Mark out hole positions using a center punch (Criteria S5.1, S5.3).
  • Drill through holes and tap internal threads (Criteria S7.2, S7.3).
  • Produce internal threads using hand taps (Criteria S7.3).
  • Tools and Equipment:
  • Drill press, hand taps, tap wrench, center punch, drill bits, and thread gauges (Criteria S10.13).
  • Assessment Criteria:
  • Hole positions and thread sizes should be within specified tolerances (Criteria S9.2, S9.8).

Objective: To drill and tap holes in a mild steel plate.

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Job 3

Tools and Equipment

Workshop task

Quiz

Measurement and Marking Out

Hand Tools for Fitting

Overview of hand fitting in engineering

Objectives

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Job 2

Drilling and Threading

  • Mark Out the Hole Positions: Use a center punch to mark the positions of the holes on the steel plate.
  • Drilling: Drill through the holes at the marked positions.
  • Threading: Use hand taps to thread the drilled holes.
  • Assessment Criteria:
Hole positions and thread sizes should be within specified tolerances.

Instructions.

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Instructions

Workshop task

Quiz

Measurement and Marking Out

Hand Tools for Fitting

Overview of hand fitting in engineering

Objectives

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Job 3

Cutting and Shaping with Hand Saws

  • Operations Covered:
  • Use a hacksaw to cut a piece of mild steel (Criteria S6.2).
  • File the edges to smoothness and square the ends (Criteria S7.4).
  • Perform measurements with a ruler and Vernier caliper (Criteria S10.3, S10.4).
  • Tools and Equipment:
  • Hacksaw, file, ruler, Vernier caliper.
  • Assessment Criteria:
  • Length within ±0.25mm, square edges, and smooth finish (Criteria S11.2, S11.4).

Objective: To cut a piece of mild steel to length and shape it using a hand saw.

Job 4

Tools and Equipment

Workshop task

Quiz

Measurement and Marking Out

Hand Tools for Fitting

Overview of hand fitting in engineering

Objectives

Home

Job 3

Cutting and Shaping with Hand Saws

  • Cutting: Use a hacksaw to cut a piece of mild steel to the required length.
  • Filing: File the cut edges to smoothness and ensure the ends are square.
  • Measurement: Use a ruler and Vernier caliper to measure the final length and check the squareness of the ends.
  • Assessment Criteria:
Length within ±0.25mm, square edges, and smooth finish.

Instructions

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Instructions

Workshop task

Quiz

Measurement and Marking Out

Hand Tools for Fitting

Overview of hand fitting in engineering

Objectives

Home

Job 4

Producing a Simple Mating Part

  • Operations Covered:
  • Mark out the chamfer and the hole position (Criteria S5.1, S5.6).
  • Cut the chamfer with a file and drill the hole (Criteria S7.1, S7.9, S7.3).
  • Tap the hole and check for fit with a matching screw (Criteria S7.3).
  • Tools and Equipment:
  • Files, drill press, taps, thread gauges, chamfer gauge.
  • Assessment Criteria:
  • Chamfer angle within ±1 degree, thread fit to BS Medium fit (Criteria S11.6).

Objective: Produce a simple mating part with a chamfer and an internal threaded hole.

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Tools and Equipment

Workshop task

Quiz

Measurement and Marking Out

Hand Tools for Fitting

Overview of hand fitting in engineering

Objectives

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Job 4

Producing a Simple Mating Part

  • Mark Out: Mark the chamfer and hole position on the material.
  • Chamfering: Use a file to create the chamfer on the edge.
  • Drilling and Threading: Drill the hole and tap it to create an internal thread.
  • Fit Check: Check the fit of the screw or bolt in the threaded hole.
  • Assessment Criteria:
Chamfer angle within ±1 degree, thread fit to BS Medium fit.

Instructions

Quality Control

  • Regular checking of measurements against specifications
  • Use of appropriate measuring equipment for the required accuracy
  • Recognizing and rectifying marking out errors

Pipefitting Uses In pipefitting, engineering hammers are used to: Align pipe sections before welding or joining Gently tap pipes into place when making connections Remove burrs or imperfections on pipe ends Drive wedges to secure temporary pipe supports Mechanical Fitting Uses For mechanical fitting tasks, these hammers help: Assemble or disassemble mechanical components Adjust the position of parts during alignment Set bearings or bushings in place Drive out pins or keys when removing parts Welding Applications In welding work, engineering hammers are utilized to: Remove slag and spatter after welding Straighten or shape metal before or after welding Tap welded joints to test for soundness Position and align parts prior to tack welding The soft face of engineering hammers allows for striking metal surfaces without causing damage or leaving marks. This makes them ideal for delicate adjustments and positioning of components in these fields. The controlled force they provide is crucial for precise fitting and alignment tasks in pipefitting, mechanical assembly, and welding preparation.

  • Proper handling of sharp marking tools
  • Maintaining a clean and organized work surface
  • Using appropriate personal protective equipment (PPE)

Tools used for measuring: Rules and tape measures Calipers (vernier, digital, dial) Micrometers Squares Protractors Height gauges

Hand fitting techniques are used to produce components with various features, including: Flat, square, parallel and angular faces Radii and curved profiles Drilled holes Internal and external threads Sliding or mating parts

  • Flat, square, parallel and angular faces
  • Radii and curved profiles
  • Positions for drilled holes
  • Locations for internal and external threads

Features to be marked out

Hacksaw

  • Versatility: Hacksaws can cut through a wide range of metals and are suitable for various projects.
  • Cost-Effective: They are inexpensive and do not require power, making them accessible for small-scale or DIY projects.
  • Manual Operation: Cutting with a hacksaw requires physical effort and can be time-consuming compared to power tools

Tools used for marking out: Scribers Punches (center punch, dot punch) Dividers Chalk or marker pens Surface plates or marking tables

Techniques:

  • Use of datum points and lines
  • Marking out from drawings or specifications
  • Use of templates or patterns
  • Applying tolerances during marking out