Sophie Paveling

Handfitting Questions

Producing components using hand fitting techniques

1) Describe the health and safety requirements and safe working practices and
procedures required for the hand fitting activities undertaken.
When performing any hand fitting job there are many safety requirements that need to be
undertaken to ensure that the all personnel are safe and are in no risk. Such things include
wearing the correct P.P.E, and informing all surrounding people on the job that you are to
perform e.g. using the drill.
Alongside this a risk assessment is to be created on the area that is to be worked on, this will
analyse all machinery, tools and space identifying all risks and health hazards.

2) Describe the importance of wearing appropriate protective clothing and

equipment (PPE), and of keeping the work area safe and tidy
Wearing the correct P.P.E is extremely important, this will protect the person from getting
trapped or hurt in any way. Examples of this include: wearing overalls and sometimes safety
glasses to protect the skin from getting infected by the swarf off the material. Another
example would be wearing safety boots with steel toe cap to ensure that the feet are protected
from any potential falling objects.
Keeping the work area safe and tidy is also extremely important, this will eliminate any
potential damage to all personnel in and around the area. The swarf can easily pierce the skin,
therefore the sides must be wiped clean and all swarf is to be removed to eliminate the risk of
someone leaning on it or touching it.

3) Describe the hazards associated with the hand fitting activates (such as use of
power tools, trailing leads or hoses, damaged or badly maintained tools and
equipment, using files with damaged or poor fitting handles), and how they can
be minimised.
The hazards associated with hand fitting activities include the use of: power tools- These can
be extremely temperamental, they must be only used by a competent or trained personnel, if
they get used by someone who has no knowledge on how to use it, it puts all others in risk of
getting hurt. Trailing leads- these are a large trip hazards, if someone has no knowledge of the
cabling being there they could potentially fall over and damage themselves. This incident will
also happen when considering hoses around the work shop, they must be placed in a
designated place safely away from everything.
Damaged or badly maintained tools and equipment can cause damage to not only the person
using it but other people surrounding. If a tool is broken e.g. a hammer head has become
loose to the handle, it runs the risk of coming off the handle and potentially hitting other
people. To minimise all these issues, checks must be -performed on the tool work before use.

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Handfitting Questions

4) Describe the procedure for obtaining the required drawings, job instructions and
other related specifications.
All documentation for the job is located in the cabinets, if any job instructions are required
they will be provided by a competent personnel or will be supplied with the job request.

5) Explain how to use and extract information from engineering drawings and
related specifications (to include symbols and conventions to appropriate BS or
ISO standards), in relation to work undertaken.
On the documentation given for the task, there is a drawing of the finished object. On the
drawing there is a 1st and 3rd view. The 1st view is the Eye-Object View the 3rd view is the
Eye-View-Object view.
The drawing also has specified measurements, these measurements are measured in imperial
or metric. Imperial is: Feet, Inches and Yards, metric is: Millimetres, Centimetres and
Meters.
All these drawings are to be t the British standards, to ensure they are to spec there is a
number written on the drawing e.g. BS8888 this states the drawing is written to the required
specifications of the BS. Examples of the symbols in the drawing include: the circle with the
line cutting through it, this symbol represents the diameter, the R stands for the radius.

6) Explain how to interpret first and third angle drawings, imperial and metric
systems of measurement, workpiece reference points and system of tolerance.
The Datum is the reference point where all measurements are to be taken from. This datum
edge is to be filed down until it is flat and provides very accurate measurements.
Tolerances are placed on all components to ensure that the required work piece is made
correctly and is to the specifications of the job. The tolerances change all the time but can
vary dependent how important the work piece is, tolerances can include 0.25mm. If this
tolerance was to be put in practise with a 60mm length bar, the minimum it can be cut to is
59.75mm and the maximum would be 60.25mm.
On the documentation given for the task, there is a drawing of the finished object. On the
drawing there is a 1st and 3rd view. The 1st view is the Eye-Object View the 3rd view is the
Eye-View-Object view.
The drawing also has specified measurements, these measurements are measured in imperial
or metric. Imperial is: Feet, Inches and Yards, metric is: Millimetres, Centimetres and
Meters.

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Handfitting Questions

7) Explain how to prepare the materials in readiness for the marking out activities,
in order to enhance clarity accuracy and safety (such as visually checking for
defects, cleaning the materials, removing burrs and sharp edges, applying a
marking out medium).

When the material has been collected for the job, a few checks are to be made to ensure that
the quality of the material matches the specifications. These checks include: measurementthe material should be measured to ensure that it is fit for purpose and the person performing
the job can make the piece using that size material. Another check includes visually
inspecting the material for any burrs or defects, this can include deep scratches or dents in the
material; dents and scratches may affect the end product. If there are any burrs on the material
they can easily be removed using a file.
Once all checks are done and the material has no defects the material is to have a small layer
of engineers blue applied to it, this dye will allow people to mark out the measurements on
the material accurately.

8) Explain how to select and establish a suitable datum; the importance of ensuring
the marking out is undertaken from the selected datum, and the possible effects
of working from a different datum.
The datum edge needs to be a flat edge of the material, this edge will need to be filed down
and measured against a 90degrees square to ensure that the edge is completely flat and has no
uneven edges or bumps. From this edge all measurements can then be taken, these
measurements will be extremely accurate due to the flat surface. To ensure that, that certain
edge only gets used a recommended marking should be placed on it displaying its function.
If measurements were done off any surface edge then they will be inaccurate and run the risk
of not reaching the specifications of the job aligned.

9) Describe the methods of holding and supporting the workpiece during the
marking out activities, and equipment that can be used (such as surface plates,
vee blocks and clamps, parallel bars, screw jacks).
When marking out the material a few accessories are available to use to ensure that the
material is stabilised and secure; increasing the accuracy of the marking outs. These piece of
equipment include: surface plates- surface plates are used when the material needs to be
pushed against something to ensure there is a flat edge and the measurement will be straight.
Another piece of equipment is the V-Block, this is used when the material needs to be
stabilised also. The material is place within the V part of the block, this allows the person to
use the gauge to gather where the bottom of the piece is and measure up however far needed.

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Handfitting Questions

Clamps are also used, these will hold the material down to the marking out table. They
provide stability to the piece and will ensure it wont move when marking out is being
performed.

10) Describe the use of marking out conventions when marking out the workpiece
(including datum lines, cutting guidelines, square and rectangular profiles,
circular and radial profiles, angles, holes which are linearly positioned, boxed
and on pitch circles).
Pitch circle diameters are a series of holes marked out around a given diameter the holes are
equally spaced apart (angularly) and reference books such as a Zeus book can be used to
establish the hole positions.
Radial and circular profiles can be marked out using steel dividers and then cut and filed to
establish the correct profile (the radius can be checked using a radius gauge).
Holes on a linear axis can be marked from a datum edge to a singular point meaning that all
holes come from the datum edge.

11) Describe the ways of laying out the marking out shapes or patterns to maximise
use of materials.
A way of maximising the use of material is to cut out accurate templates of the shapes needed
to be cut, these templates can then be arranged on the material allowing visual measurements
on what you can cut and where to ensure as much material is saved as possible.
Another way to save material is to always start the shape from the edge, this way it wont
leave an awkward shape that cant be used for anything else.
12) Describe the need for clear and dimensional accuracy in marking out to
specification and drawing requirements.
It is extremely important to ensure that all marking out is clear and the dimensions are very
accurate. All material cut outs must be within the specified tolerances, if the marking out is
not done accurately they run the risk of drawing the material out of spec therefore it wont be
accepted.
13) Explain how to set and adjust tools (such as squares, protractors and verniers).
Vernier Caliper- The Vernier Caliper has main jaw that are used for measuring external
diameter, as well as smaller jaws that are used for measuring the internal diameter of objects.
To set up this tool, the first thing to do is to unlock the screw, this will loosen the caliper
allowing you to extend and retract, then close the jaws (this is for calibration reasons), the
reading should be 0, if not, then the reading will not be accurate.
Square The engineers square is a simple measurement tool used to measure the datum edges
and display if the edge is flat or not. This Engineers Square needs to be cleans before use to
enhance the accuracy. Once cleaned the object is to be pushed against the vertical side of the

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Handfitting Questions

engineers square then pushed up to the vertical side keeping the material square. It is
recommended that the engineers square is to be pointed towards the light; any light that
travels through shows a different surface level.
A protractor is a simple measuring to set up and adjust. This measurement tool has a centre
point, this centre point must be placed flush with the starting line of where youd like to have
the angle at.
14) Describe the importance of using tools only for the purpose intended; the care
that is required when using the equipment and tools; the proper way of storing
tools and equipment between operations.
Every tool is made to perform a specific job, it is not made for multiple jobs e.g. a file is
made to file down a material to a certain size or to smooth a surface. This tool must not be
used for any other purpose; it can become very dangerous. If someone chooses to use a file as
a hammer then there is the risk of the file head coming out of the handle socket. The file is
not placed in to the handle as securely as a hammer. If the file is to come out of the handle it
runs the risk of flying off and hurting the surrounding people or damaging machinery.
When finished with the tool it should be checked over to ensure that there is no damage to it
and it is safe for the next person to use.
When finished with the tool and it is safe it should be stored in a safe place that is away from
people and inaccessible to unauthorised personnel an example of this would be a cupboard
with a lock on.
15) Describe the cutting and shaping methods to be used, and the sequence in which
the operations are to be carried out.
There are many cutting and shaping methods available when producing shapes on material,
examples of this include:

Saws hacksaw provide a fine tooth approach to cutting material. This device is
driven by hand and the direction of cut can be adjusted during the cut depending what
shape has been requested. This method however can leave a rough edge and will need
to be smoothed down with a file.
Following the hacksaw there is the coping saw, this saw is used for far more intricate
shapes, or thinner material. This saw can be used following the hacksaw to finalise the
shape and add extra detail.
Tin snips these can be used to cut the material to the required shape, they will
however leave sharp edges and quite a rough look, they will need to be followed by a
file.
The drill this provides any form of shape required dependent on the drill piece
selected. This will provide internal shapes.

Sophie Paveling
Handfitting Questions

16) Describe the various types of file that are available, and the cut of files for
different applications.
Types of file include:

Hand File This is used for general filing of metals such as steel. They have a
rectangular section and are most common in workshops.
Half Round File This file is used for filing curved surfaces. The shape of this file is
a normal shaped round file with one side flat. This is perfect for creating curved
edges.
Three Square File This file is triangular in section and is extremely useful when
filing tight corners/angles.
Knife File This file is used when there is very little space.
Square File This file is used for making slots in material.

17) Describe the importance of ensuring that file handles are secure and free
embedded foreign bodies or splits.
The file handle hold vast responsibility when it comes to the operation of the tool. The file is
slotted into the handle for stability. If the handle has any form of crack or chip in it, it can
cause implications such as the handle can become lose to the file or the handle may cause
injuries such as cuts or splints. Following this, before use of the tool the handle and file are to
be checked. If the handle is lose from the file it must be sent off for repair and not used.
18) Explain how to prepare the components for the filing operations (cleaning, deburring, marking out)
Before the component is to be filed various things need to be performed on the material first,
these include:

Cleaning the material removal of excess material e.g. dirt, rust or mould.
Remove the burrs Remove all sharp surfaces or excess material using a file or a
deburring tool.
Dying the material The material is to have engineers dye put on it to allow marking
out to be clear.
Marking out Using a making out table, rule, scribe and other measuring tools
required marked out the measurements for the component.

19) Describe the use of vice jaw plates to protect the workpiece from damage.
Vice Jaw plates are inserted in to the vice and rest on the gripping plates. The jaws are used to
protect and hold the material in place while it is being worked on. These jaw plates have a
rubber surface, this surface protects the material from any dents/scratches that can be created
from the force of the vice.

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Handfitting Questions

20) Explain how to file flat, square and curved surfaces, and how to achieve a
smooth surface finish (such as by draw filing, the se of abrasive cloth, lapping
using abrasive pastes).
To file flat the following is to be performed: The file is to be held by both hands and is to be
held flat against the surface. This is then pushed forward and the cut is made on the forward
stroke. The file then needs to be lifted and returned to the starting point. If the file hasnt got a
good surface finish draw filing will achieve this. Draw filing is: holding the file with both
hands on each end of the blade, the blade is then pushed forward and back on the material.
To file a square surface a square file or a flat file is to be used. These files will ensure that the
flat surface will stay flat. The square 90 degree corner will come with the straight filing. This
can be measured using an engineers square.
To file a curved surface or produce a curved surface a round or half is to be used. These files
will follow the already made curve or will indent the material enough to form the required
curve. To smooth the curved surface down abrasive cloths can be used, these will remove the
excess material on the surface and make it all level making it smooth.

21) Explain how to select saw blades for different materials, and how to set the
blades for different operations (such as cutting externally and internally).
On a hacksaw there are many types of blades, these blades are different in many ways, one of
the ways is through the amount of teeth it has:

A 14TPI blade is used for cutting large sizes, aluminium and other soft metals.
A 18TPI blade is used for general workshop cuttings
A 24 TPI is used for cutting steel plate up to 5/6mm
32TPI is used for cutting the hollow sections and tubing.

When cutting externally the blade will be facing outwards towards the material and it will be
cut that way. If an internal cut is to be processed, the blade itself can be taken out of the
handle, placed through the hole facing the way it is to be cut and attached back on to the
handle, the hacksaw can then be used to cut the inside of the hole to form the required shape.
22) Explain how to cut external threads using hand dies, and the method of fining
and adjusting the dies to give the correct thread fit.
When producing an external thread a hand die is to be used, this hand die has teeth, these
teeth hold on to the material and when turned it produces the external thread.
When the hand die is being turned, it must have a vast amount of lubrication applied to it, this
is due to the heat of the material becoming hot and expanding it can also dry quickly and re
stick to the material; this can break the hand die.
When turning the hand die it must be brought back after every two turns, this is because of
the built up of swarf. The routine is 2 turns forward, half a turn back. If this procedure is not
performed then the hand die will become blocked and break.

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Handfitting Questions

23) Explain how to determine the drill size for tapped holes, and the importance of
using the taps in the correct sequence.
When creating a tapping holes there is a chart that displays the drill and tapping size
comparison. This table clearly displays what thickness is needed to be left for the tap to go
through. If I was to produce a tap I would go to this table and see what size drill piece is
needed. When tapping the hole or external thread, there are three steps within the sequence.
Through the three steps the thread gets thicker, and cuts more into the material. These steps
need to be followed, if not follows it runs the risk of snapping the tap or damaging the
material.
24) Explain how to prepare drilling machines for operations(such as adjustment of
table height and position; mounting and securing drills, reamers, countersink
and counterbore tools in chucks or morse taper sockets; setting and adjusting
spindle speeds; setting and adjusting guards/safety devices.
When setting up the drill various things are to be processed before any operation is to be
performed, these include:

The first thing to do is to adjust the table height to the correct height. The correct
height is discovered by the amount the drill can come down and if it can travel
enough distance.
The position of the table is determined by what part of the material needs cutting
or if the material is too big for the minimum table height adjustment.
The material is then to be mounted and secure down with the clamps.
Depending on the material and size of the drill the speed and feed will be adjusted
to fit. There is a chart displaying these figures next to the drill.

25) Explain how to mount the workpiece (such as in a machine vice, clamped to
table, clamped to angle brackets); techniques of positioning drills to marking
out, use of centre drills and taking trial cuts and checking accuracy, and how to
correct holes which are off centre.
A machine vice is used on a drill or milling machine. When used on the drill its main duty is
to position the material in the correct place and secure it while it is being worked on. To
mount the workpiece on the machine vice the machinist is to place it in and secure it in a
certain way and secure it themselves.
Once it is in the machine vice, this vice is to be clamped to the table. There are small screw
clamps on the drill that grip the vice and hold it down to the table. These are to be tightened
up until the vice cant be moved.
When setting up the drill piece, the drill is to be placed in the clutch and tightened up. Once
tightened up the drill should manually be pushed down and up and positioned accordingly to
the centre drilled hole or hole punch.

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Handfitting Questions

A trial cut can be taken if accuracy is key, this form of cut only takes a small later of the
material off and gives an indication on where the drill piece is in comparison to the marked
hole.
If a hole is off centre when punching it with a punch and hammer a simple slant on the punch
will moved the dented hole to the correct position, then in the new position a straight punch is
to be done.

26) Explain how to produce a sliding or mating fit using filing, scraping and lapping
techniques.
Fits of this kind are intended for the accurate location Parts made to this fit turn and move
easily.
To produce a sliding fit the following techniques can be used:

Filing There are a large variety of different shaped files each with a different job

and ability. There are flat files used to file flat surfaces and curved to create a
curved surface. Dependent on the sliding fit these files will be used to create it.
The two pieces of material will need to continuously be checked with each other
when filing is being performed.
Scraping This method is essentially like using a scraper. It is a blade with an
edge folded over and will give a smooth finish and remove excess material with
ease.
Lapping - Lapping is used to create a very fine surface finishing. The purpose of
this technique is to remove any unwanted scrapes or marks that are very minor.
This is the final technique used to create the perfect fit.

27) Describe the problems that can occur with the hand fitting activities, and how
these can be overcome (such as defects caused by incorrectly ground drills,
inappropriate speeds, and damage by work holding devices).
If the component is to be drilled and the drill piece used is blunt or has seized, it runs the risk
of damaging the material itself or not cutting into it at all. This can be corrected by sharping
the drill on a grinder or if not trained retrieving another drill piece that is sharp. If the drill
piece has already damage the material then the correction to be made is to (if not drilled in
too far) repeat the process on the other side of the material, drill the hole through the other
side, or if possible drill a bigger hole and adjust the other side of what the component is
connected to.
If the drill is on the wrong speed then it will run the risk of getting stuck in the material or
braking the drill piece. If the drill is stuck in the material, it can be drilled out with another
drill bigger than that one. If the drill bit has just snapped and come off the drill piece is to be
replaced and the speed will need to be adjusted.
The work holding devices can cause indents on the material, these indents can affect the
operation of the material or make it look rough. If there are slight indents on the material then

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Handfitting Questions

these can be removed using a file. To avoid the potential damage there are covers available to
place over the jaws of the vice or blocks of wood can be placed around the component.

28) Explain when to act on their own initiative and when to seek help and advice
from others
A person shall only act on their own initiative when they are qualified and competent enough
to perform the job without assistance. If they feel that they are not trained enough or they
begin to question the job they are performing they should question a trained personnel for
advice or guidance.
29) Describe the importance of leaving the work area in a safe and clean condition
on completion of the fitting activities (such as removing and storing power leads,
isolating machines, removing and returning drills, cleaning the equipment and
removing and disposing of waste).
It is extremely important for the work area to be left in a safe and clean condition. All excess
debris must be removed and all tools should be put back into the allocated location. If this
task is not performed it runs the risk of someone coming over and getting swarf in their skin
or clothing, also it runs the risk of an unauthorised and untrained personnel using the
equipment.