SYLLABUS FOR FITTER GENRAL INFORMATION 1. Name of the Trade : FITTER 2. N.C.O. Code No. : 842.10, 842.15. 3. Entry Qualification. : Passed in VIII Class Examination under 10 + 2 System of education or its equivalent. 4. Duration of Craftsman : Two years. 5. Duration of Apprenticeships : 3 years including Basic Training of one year. 6. Rebate to Ex-I.T.I Trainees : (a) 2years for Ex-ITI Fitter (b) 1 year for Ex-ITI (c ) 2 years for Ex-ITI Tool and Die Maker. 7. Ratio of Apprentices to : 1:7 Workers .
Transcript
SYLLABUS FOR FITTER
GENRAL INFORMATION
1. Name of the Trade : FITTER
2. N.C.O. Code No. : 842.10, 842.15.
3. Entry Qualification. : Passed in VIII Class Examinationunder 10 + 2 System of education
orits equivalent.
4. Duration of Craftsman : Two years.
5. Duration of Apprenticeships : 3 years including Basic Trainingof one year.
6. Rebate to Ex-I.T.I Trainees : (a) 2years for Ex-ITI Fitter(b) 1 year for Ex-ITI(c ) 2 years for Ex-ITI Tool
and Die Maker.7. Ratio of Apprentices to : 1 : 7
Workers .
WEEKNO.
PRACTICAL THEORY ENGINEERINGDRWAING
WORKSHOPSCIENCE ANDCALCULATION
1 2 3 4 51 Familiarization
with the institute ,Impotence of tradetraining ,Machinery used inthe trade , types ofwork done bytrainees in thetrade, introductiono safety equipmentand their uses
Importance of softy andgeneral precaution observed inthe institute and in the section.Importance of the trade in thedevelopment of industrialeconomy of the county .Whatis the related instructionssubject to the taughtparchment to made .Recreational, medicalfacilities and other extracurricular activities of theinstitute.(All necessaryguidance to be provided to thenew comers to becomefamiliar with the working ofIndustrialTraining Institute Systemincluded stores procedures.
2 Marking out linesgripping suitable invice jaws, hacksawing to givendimension sawingdifferent types ofmetals of differenttypes of metals ofdifferent sections.
Safety accident preventionlinear measurements its unitsdividers, calipers,hermaphrodite, calipers,hermaphrodite, center punch,dot punch dot punch, theirdescription and uses ofdifferent types of hammers,description, use and care of‘v’ Blocks, marking off table.
Bench vice construction,types, uses care &maintenance, vice clamps,hacksaw frames and bladesspecification description,types and their uses, methodof using hacksaws.
Types of linestheir meaning &application asper IS-696
Properties anduses of copper,zinc, lead, tin,aluminum.
7.&8
Marking accordingto simple blueprints locatingposition of holesscribing lines onchalked surfaceswith making toolsfinding centre ofround bar with thehelp of “V” blockand marking block.Joining St. line toand arc.
Marking media marking bluePrussian blue-red lead, chalkand their special applicationdescription. Use, care andmaintenance of scribing block.
System of units,British, metricand SI units forlength area,volume, capacity,weight time,angle, theirconversions.
10 Filing flat, square,and parallel to anaccuracy of 0.5mm. Chip curvealong a line-markout, key ways atvarious angles &cut key ways.
Types of files conveningtaper, needle care andmaintenance of files, varioustypes of keys, allowableclearances & tapers; types,uses of key pullers.
---do--- Effect of alloyingelements on theproperty of C.I.& steel.
11 File thin metal toand accuracy of 0.5mm. chip chamfer.
Physical properties ofengineering metal : color,weight, structure,
Free handsketching of st.lines, rectangles,
Unit oftemperature force& related
Grooves and slots. conductivity, magnetic,fusibility specific gravity,fusibility specific gravity.Mechanical properties:ductility, malleabilityhardness, brittleness,toughness, tenacity, elasticity.
circles, square,polygons,ellipse.
problems.
12 Saw along astraight line curvedline, on differentsection of metal.Straight saw onthick section. M.Sangle and pipes.
13 File steps andfinish with smoothfile accuracy =0.25mm. File and sawon M.S. Square andpipe weds.
Micrometer outside and insideprinciple constructionalfeatures, parts graduationreading, use and care.Micrometer depth gauge,parts, graduation, reading, useand care.
Standardprinting style forletters andnumbers as perIS:696
Industrial Visit Industrial Visit Industrial Visit Industrial VisitACHIEVMENT; The trainee should be able to:1 Use fitters hand tools.2 Do simple marking out according to simple Blue print.3 Do filing\hack sawing and chipping.14 File radius along a
marked line(Convex &Concave) & match.Chip step and file.
Vernier calipers, principle,construction, graduations,reading, use and care. Vernierbevel protractor, constructiongraduations, reading, use andcare Dial Vernier Caliper.
Heat treatment necessaryvarious heat treatmentmethods such as normalizingannealing, hardening andtempering. Power hammerconstruction feature ,methodof operating and uses.
Work energy andpower ,their unitsand appliedproblems.
20 Marking of straightlines, circles,profiles and variousgeometrical shapesand cutting thesheets with snips.Marking out ofsimpledevelopmentmarking out forflaps for solderingand sweating.
Safety precaution to beobserved in a sheet metalwork-shop sheet and size.Commercial sizes and varioustypes of metal sheets coatedsheets and their uses as per ISIspecifications.
-do- -do-
21 Make variousjoints, wiringhemming, solderingand brazing fromlocked, groovedand knocked upsingle hem straightand curved edgesfrom doublehemming. Punchholes-using hollowand solid punches.Do lap and buttjoints.
Marking and measuring tools,Wing compass, Prick punch,tin man’s square tools, snips,types and uses. Tin man’shammers and mallets type-sheet metal tools, stakes-bench types , parts their uses.Soldering iron ,types,specifications, uses. Trammel,description ,parts, uses. Handgrooves specifications anduses.
Obliqueprojection ofsimplegeometric-alsolids.
Percentage,changingpercentage todecimal andfraction and vice-versa. Appliedproblems.
22 Bend sheet metalinto variouscurvature - formwired edgesstraight & curvesfold sheet metal atan angle usingstakes ,Bend sheetmetal to variouscurvature makesimple square –container withwired edge and fixhandle .
Solders – composition ofvarious types of solders andtheir heating media ofsoldering iron . fluxes : types,selection and application –joints wiring various types ofmetals joints, their selectionand application tolerance forvarious joints, their selectionand application.
Obliqueprojection ofsimplegeometricalsolids.
Problem onpercentagerelated to trade .
23 Make square traywith squaresoldered cornermake funnel as perdevelopment &solder joints. Makeriveted left & beltjoint.
Rivets – tin man’s rivets ,types, size, selection forvarious work.Riveting tool, dolly, snaps,descriptions and uses. Methodof riveting shearing machinedescription, parts and uses
Different types ofload, stress,strain modulus ofelasticity
24 Striking andmaintaining arc,straight line head
Safety – importance of safety&general precautionobserved in a weldingshop.precaution in electric &gaswelding(before,during,after)introduction to safetyequipment and their uses
Isometricdrawing ofsimple machineand castingblock s
25 Make squarae buttjoint and ‘T’ filletjoint-gas and arc.dosetting up offlames, fusion runswith and withoutfiller rod,gas andarc.
Hand tools:hammers,weldingdescription, types and uses,machine and accessorieswelding transformer, weldinggenerators, descriptionprinciple, merhod of operating
26 Make square battjoint and ‘T’ filletjoint-gas and arc.
H.P.welding equipmentdescription, principle methodof operating L.P weldingequipment, description,principle, method of operatingtypes: joints-Butt and fillet asper BIS specifications.
Free handsketches of traderelated handtools measuringtools.
Ratio &proportion,Ratio, findingforms and ratioproportions,direct proportionand indirectproportion.
27 Do gas cutting. Oxygen cutting machinedescription, parts, uses,method of handling cuttingtorch-description, partsfunction and uses. Gases andgas cylinder description.Kinds main difference anduses
ACHOEVEMENT: The trainee should be able todo:1. Simple jumping, drawingand bending.2. Simple heattreating operations likehardening, tempering andannealing. 3. Simple squarecontainer, round containerwith wired edge and fithandle. 4. Rivet lap and buttjoint. 5. Butt and fillet welds-gas and arc. 6. Gas cutting.
Safety precautions to beobserved while working on alathe. Lathe specifications,and constructional features.Lathe main parts-descriptions,bed, head stock, carriage, tailstock, feeding and threadcutting mechanisms. Betweencentre work catch plate, dig,simple description of a facingand roughing tool and theirapplications.
29 Grind the facing,parting and formtools, plain turn,step turn, holdingjob in three jawchuck- Deburr,chamfer-cornerround the ends,Shoulder turn :square filletedbeveled under cutshoulders.
Lathe cutting tools Brier studyof the ncmenclature of Lathecutting tools and necessity ofcorrect grinding, solid andtipped, throw away type toolscutting speed and feed andcomparison for H.H.S.,carbide tools. Use of coolantsand lubricants.
30 Cut groves square,round ;V; groove,Make a mandrel-turn diameter tosizes. Knurl the job
Chucks and chucking theindependent four jaw chuck.Reversible features of jaws,the back plate, Method ofclearing the thread of thechuck-mounting anddismounting chucks chuckingtrue face plate drilling inmethod of holding drills in thetail stock, Boring tools andenlarement of holes.
Orthographicdrawings,application ofboth the firstangle and thirdangle. Method inrepresenting thedrawing forsimple andcomplexmachine givenfor exerciseswith dimensions.
Algebraicsymbolsfundamentalalgebraoperations. Signand symbols usein algebracoefficient terms.And unliketerms.
31 Bore holes-spotface, pilot drill,enlarge hole, usingboring tools make abush. Step bore-cutrecess turn holediameter to sizes.
General turning operationsparallel or straight, turning.Stepped turning grooving,shape of tools for the aboveoperations. Appropriatemethod of holding the tool ontool post or tool rest Knurlingtoolsdescription,grade,uses,speedand feed coolant for knurling.
Grinding wheel : Abrasivegrift grade structure bondspecification us mounting anddressing Bench grinder partsand use-radius gauge filletgauge material construction,parts fraction and metricdifferent dimensions convexand concave uses care andmaintenance.
Factors anddifferent types offactorization.
37 Make the circles bybridging apreviously drilledhole. Test angularmatch up.
Radius gauge feeler holegauge, and their uses.
Standare methodof sectioning asper IS : 696Exercises fordifferentsectional viewson the givenorthographicdrawing ofmachine parts,castint etc.
Equations simplesimultaneous.
ACHIVEMNT : The trainees should be able todo:1 Chucking centeringplain turning taper boring andthread cutting. 2 Positionmarking fit contours andgeometrical figures and makemale and female parts.
38 Inside square fitmake combinedopen and sliding fitstraight sides :T: fit
Vernier height gauge :material construcetion, partsgraduations (English &Metric) uses care andmaintenance pig iron :manufacturing process (Blastfurnace) Types propcrties anduses.
Interconversionofisometricoblique drawingsto orthographicdrawings andvice-versaRelatedproblems such a“V” blockoriented byvariousmachiningoperation etc.
Equations simplesimultaneous,quadratic.
39 File fit combinedopen angular andsliding sides. Fileinternal angles 30minutes accuracyopen angular fit.
Cast iron : manufacturingprocess (cupola furnce) typesproperties and uses. Wroughtiron: manufacturing process(Fudding and Astor process )properties and uses.
40 Make sliding fitwith angles otherthan 90 sliding fitwith an angle.
Steel : manufacturing processplain carbon steels typesproperties and uses.
-------do-------- Atmosphericpressure pressurepressure andabsolute pressureand their units.
41 Make simplebracket by bendingand twistingnonferrous metsl.Drill small hole(2mm) Drill holeson sheet metal,bend sheet forround bracket.
Non-ferrous metals (copper,aluminium tin, lead, zinc.)properties and uses.
-------do-------- Lo garithms anduse of logarithmstables :Logarithms:logarithm andexponent.
42 Form internalthreads with taps tostandars size(through holes andblind holes) Drillthrough hole andtap drill blind holeand tap; preparestuds and bolt.
Screw threads : itsterminology parts, types, andtheir uses. Screw pitch gauge :material parts and uses , TapsBritish standard (B.S.W.,B.S.F., B.A & B.S.P) andmetric\BIS (course and fine)material parts (shank boadflute cutting edge) Method ofusing and use of calculatingtap hole sizes. Tap wrench :material parts types (solid &adjustable types) and theiruses removal of broken tap,studs (tap stud extractor).
----do--- Use oflogarithms andanti-logarithmtable.
43 From externalthreads with dies tostandard size.Prepare nuts andmatch with bplts.
Dies : British standard metricand BIS standard material,parts, types, Method of usingdies. Die stick: material partsand uses.
-----do----- Artothmeticaloperationsinvolvinglogarithms in thecomputations.44
44 Counter sinkcounter bore andream split fit (threepiece fitting)
Simple repair work.Simple assemblymachine parts fromblue prints.
Revision simple estimation ofmaterials use of hand booksand reference table.
Solution ofNCVT test paper(preliminary)Revision.
Revision.
52 Test TestACHIEVEMENT: TheTrainee should be to do:1. Drill holes, counter boreand spot face.2. Sharpen drill.
3. Use height and depthgauge micrometer and vernircalipers to an accuracy of1\1000\100mm.4. Mark panch cut, chip, andfile jobs as per blue prints asper blue prints and able tofinish an accuracy of0.003’\0.08mm
Test(Preliminary)
5. Operate a banch drill andto drill ream holes.6. Use of taps and dies.
53 Prepare triangle,hexagon on ends ofa cylinder barprepare female endand fit.
Keys and keyways. Typesand their uses construction(shape).
Revision of firstyear topics.
Revision of 1st
year course.
54 Make key andkeyways on theshaft and fit. ;V;grooves and slotson the cast ironblock
Spring material types anduses.
------do------ -------do------
55 Make riveted joints(lap and butt joints)
Bolts and Nuts: Material types(Hexagonal and square head)and their uses.
Screw threadtheir standardforms as per ISI,external andinternal thread,conventions onthe features fordrawing as perISI.
Description and use.Limit gauge: Ring gauge, snapgauge, plug gauge, descriptionand use.
The Trainee should be able todo:1. Make key and key ways onthe on shaft and fit.2. Make riveted joints.3. Scrap on flat and curved .
--------do---- Plain figures-segment andsector of circleellipse, fillets.
65 File and fitcombined fit withstraight angularsurface +0.02mm,hexagonal fitting
Slip gauge : Necessity ofaccuracy set of block (Englishand Metric) Details of slipgauge. Mets 46:103:112 .Wrining and building up ofslip gauge and care andmaintenance. Application ofslip gauges for measuring,sine bar-principle, application& specification.
66 Drill and reamsmall dia holes toaccuracy-correctlocation for fitting.Make male andfemale fitting parts-drill and ream holesnot less that 12.7mm.
Lapping: Application oflapping material for lappingtools, lapping abrasivescharging of lapping tool. Surface finish importanceequipment for testing- termsrelation to surface finish.Equipment for testing surfacesquality dimensional tolerancesof surface finish.
Concept ofpreparation ofassemblydrawing anddetailing. Simpleassemblies &their details oftrade relatedtools\job\exercises with thedimensions fromthe given sampleof models. Toolpost for the lathewith washer andscrew.
Honing;Application of honing–material for honing toolsshapes, grades-honingabrasives. Frosting its am andthe methods of performance.
-------do------- Trigonometry:trigonometricalratios use oftrigonometricaltable.
69 Make a snap gauge+ 0.02 mm.
Interchangeability : Necessityin Engg. Field definition BISDefinition, types of limitterminology of limits and fitsbasic size, actual size,deviation high and lowlimitzero ine, tolerance zone.
Details andassembly of vee-blocks withclamps.
Area of triangleby trigonometry.
70 Scrape angularmating surface,scrap on internalsurface.
Different standard systems offits and limits. Britishstandard system. BIS system.Method of expressingtolerance as per BIS.
Details assemblyof vee-blockwith clamps.
Finding heightand distance bytrigonometry.
71 Practice in dovetailfitting assemblyand dowel pinsIndustrial visit
Fits: Definition, types,description of each withsketch.
Details ofassembly ofshaft and pulley
Application oftrigonometry toshop problems.
72 Preparation of gapgauges.
Manufacture : the name andtypes of gauge commonlyused in gauging finishedproduct Method of selectiveassembly “Go” system ofgauges, hole plug basis ofstandardization.
Bearing introduction.Classification (journal andThrust Description of eachball bearing: sigle row doublerow, description of each,advantages of double row.
Details ofassembly ofbush bearing.
Tringle of forces,parallelogram offorces.
74 Scrap cylindricalbore and to make afit make a cotter jibassembly.
Roller and needle bearings:Types of roller bearingDescription & use of eachMethod of fitting bal androller bearings.
Details ofassembly bushbearing.
Composition andresolution offorces.
75 Scrap cylindricaltaper bore checktaper angle (flat)with sine bar.
Bearing metals types,composition and lubricantspupose of using differenttypes description and uses ofeach type.
--------do-------- -------do--------
76 Preparation ofcentre squares, drillgauges.
ACHOEVEMENT
Synthetic materials forbearing: The plastic laminateand materials, their propertiesand uses in bearings such asphonolic pejlon polymide(nylon)
The Trainee should be able todo:1. File to an accuracy of +0.04mm on flat surfaces andon angular surfaces +5minutes.
-------DO----- -----do-----
2. Drill and ream to +0.04mm.3. Fit dowel pin, studs, boltsand dovetailed sides etc.4. Use of slip gauges inspectangles to +1 minite.5. Remetal, scrap andassemble bearings.
77 File and fit straightand angularsurfaces internally
Hardening and temperingpurpose of each method,tempering colour chart.
79 Flaring of pipesandpipe joints-heattreatment of coldchisels.
Case hardning and carburizingand its methods-process ofcarburizing (solid liquid andgas)
Details andassembly ofsimple hand vice
Centre of gravity,simpleexperimentaldeterminationstable unstable &neutralequilibrium-simpleexplanation.
80 “H” fittingexercises onlapping of gauges(hand lapping only)
Solder and solderingintroduction types of solderand Flux. Method of solderinghard solder introduction typesand method brazing.
-------do------ --------do-------
81 Hand ream and fittaper pin drillingand reaming hole incorrect lo9cation,fitting dowel pinsstud, and bolts.
Production of gaugestemplates and jigs. The objectof importance for preparinginterchangeable components.
---------do------ Friction coefficient offriction
82 Simple jigs andfixtures for drilling.
Drilling jig constructionalfeatures, types and uses.
Blue printReading simpleexercises relatedto missing lines.
Simple problemrelated tofricetion.
83 Prepare a “V”block and clamp.
Fixtures-constructionfeaturestypes and uses.
Blue printreading. Simpleexercises relatedto missing lines.
Magneticsubstancesnatural andartificialmagnets.
84 Marking out as perblue print drillingstraight and curvefiling threadingwith die cutting soltcutting internalthreads with tapsmaking andadjustable spanner
Revision. Blue printreading simpleexercises relatedto missingviews.
Method ofmagnetization.Use of magnets/
85 Cutting &Threading of pipelength Fitting ofpipes as per sketchconditions used forpipe work to befollowed. Bendingof pipes cold andhot
Pipes and pipe fittingcommonly used pipes. Pipeshending fixture pipe threadsstd. pipe threads die and tappipe vices
Blue printreading simpleexercises relatedto missingviews.
87 Practice in handlingfire extinguishersof different typesrefilling ofextinguishers.
Fire precautions causes andtypes of fires precautionsagainst out break of fire. Rireextinguishers types and uses.
Simple exercisesrelating tomissingsymbols.
Simple electriccircuits simplecalculations.
88 Marking detailinclude male &female screwcutting male andfemale fitting parts.Making andtempering .
Working material withfinished surface as aluminium,duralumin stainless steel, theimportance of keeping thework free from scratdes or rustand corrosion. The variouscoatings used to protectmetals, protection coat by heatand elecetrical deposittreatments.- Treatments and provide aplasing finish as chromiumsilver plating and nickelplating and galvanizing.
ACHIVEMENT: The Trainee should be able todo:1. Carry out simple plumbingassembly.2. Make simple jigs andfixtures.3. Make male and female partsof regular contours includingtongue and groove, dovetailedsilde to and accuracy of +0.04mm.
89 Exercise onfinished material asaluminium outcatting to sizedrilling etc. withoutdamage to surfaceof finished articles.
Aluminium and its alloysUsed advantages and disad-vantage : weight and strengthas compared with steel.
Simple exercisesrelated tomissing section.
Graphs: Abscissaand ordinates,graphs of straightline, related totwo sets ofvaryingquantities.
90 Making out forangular outlines-filing and fittingthe inserts intogaps. Making asiple drilling jigMarking out-filingto line drilling andrapping brass andcopper jobs.
Tapers on deys and cotterspermissible by variousstandards. Discuss non-ferrousmetals as brass, phosphorbronze, gun metal, copper,aluminium etc. Theircomposition and purposeswhere and why used-advantages fir specificpurposes-surface wearingproperties of bronze and brass.
Power transmission elements.The object of belts-their sizesand specifications-marerials ofwhich the belts aremadeselection of the type ofbelts with the consideration ofweather load andtensionmethods of joiningleather belts.
Vee belts and their advantagesand disadvantages-Usecommercial belts dressing andredin-creep and slipping-cal-culations.
-do-
Industrial Visits.
Further practiceogarithm.
92. Complete exercisescovering theassembly of partsworking to detailsand arrangementsdrawings.Dismantling andmounting ofpulleys. Makingreplacing
Power trsansmissipns-coupling types flangecoupling Hooks couplinguniversal coupling and therdifferent uses.
Futher practicicelogarithm.
Mechanicalproperties ofmetals.
93 More difficult workin marking outincluding tangentstemplates involvingus ofvernierprotractor.
Pulley-types-solic, split and“V” belt pulleys standardcalculation for determiningsize crowing of pulleys widthof faces loose and fast pulleysjockey pulley types of drives-open and cross belt drives.The geometrical explanationof the belt drivers at and angle
---------d0------ ------do-----
94 Fitting of dovetailslides.
Power transmission by gears,most common form spur gear,set names of some essentialparts of the set-The ptchcircles Diametal pitch velocityratio of a gear set Helical gear,herring bone gears, bevelgearintg spiral bevel gearinghypoid gearing pinion andrack, worm gearing, velocityratio of worm gearing Repairto gear teeth by building upand dovetail method.
95. Male and remaledovetail fittingrepairs to gearedteeth. Repair ofbroken gear toothby stud. Repairbroker gear teethby dovetail.
Method of fixing gearedwheels for various purposedrives. General cause of thewear and tear of thetoothedwheels and their remedies-method of fitting spiral gears-helical gears-bevel gears-worm and worm wheels inrelation to required drieve.Care and maintenance ofgears.
96 Marking out on theround sections forgeometrical shapedfittings. Finishingand fitting to size,checking up thefaces foruniversality.
LaBrication and lubricants.How lubrication is done. Agood lubricant, viscosity ofthe lubricant. Main property oflubricant. How a film of oil isformed in journal. Bearingsmethod of lubrication gravityfeed, force (pressure) feed,splash lubrication. Cuttinglubricants and coolants:Solube oil soaps suds paraffinsoda water commonlubrication of lubficants.
-------do----- Transmissionpower by beltpulley & geardrive.
97 Shaping-parlledblock & W-block.
Chains, wire ropes andclutches for powertransmission. Their types andbeief description.
Solution ofNCVT testpapers.
Transmission ofpower by beltpulley and geardrive.
98 Drilling forriveting. Rivetingwith as many typesof rivet as availableuse of connter sunkhead rivets use ofcounter bore tool tofit cheese headbolts. Use of poprivets and gun.
Discuss the various rivetsshape and from of heads riveting tools for drawing up theimportance of correct headsize. The spacing of rivets.Flash riveting, use of correcttools-compare hot and coldriveting.
Revision -----do-----
99 Dimantlingremoval andreassemble of asimple machinetool. Dismantlingand assemble ofpillar type drillingmachine.
Intallation, maintenance andoverhaul of machinery andengineering equipment andalignment of machines.
Revision Solution ofNCVT papers.
100 Milling-Plain, slot& angular cutting.
Clutch: Type positive clutch(straight tooth types, angulartooth type) friction type (flatand conical type)
Revision -----do-----
101 Grinding-Surface& circular.
Washers-Types andcalculation of washer sizes.The making of joints and fittigpacking-The us of liftingappliances, extractor pressesand their use. Practical methodof obtaining mechanicaladvantage. The slings andhandling of heavy machinery.Special precautions in theremoval and replacement ofheavy parts.
Foundation bolt: types (rag,lewis cotter bolt) descriptionof each erection tools, pulleyblock, crow bar, spiritlevel,plumb bob 2+4, wirerope, manil rope, woodenblock.
-----do----- Revision
103 Revision Revision Institute Test Institute Test
104ACHIEVEMENT:The Trainess should be able to:1. Dismantle and assemble simple machine parts and accessories.2. Repair broken gear tooth.3. Make simple drilling jig.4. Erect machine.
TRADE : FITTER
List of Tools and Equipment for the first 52-weeks (1 year)
For a Batch of 16 traineesSLNO.
NAME OF THE TOOLS &EQUIPMENT
1 2 3 4 51 Rule steel 15 cm with metric
graduations1 16 17
2 Square try 10 cm blade 1 16 173 Caliper outside 15 cm spring 1 16 174 Caliper inside 15 cm spring 1 16 175 Caliper 15 cm hermachrodite 1 16 176 Divider 15 cm spring 1 16 177 Scriber 15 cm 1 16 178 Punch centre 10 cm. 1 16 179 Screw driver 15 cm. 1 16 1710 Chisel cold 10. 1 16 1711 Hammer ball pein 0.45 kg. with
handle1 16 17
12 Hammer ball pein 0.22 kg.with handle 1 16 17
13 File flat 25 cm second cut 1 16 1714 File flat 25 cm smooth 1 16 1715 File flat round second cut 15 cm 1 16 1716 Hacksaw frame adjustable 20-30 cm 1 16 1717 Safety goggles 1 16 1718 Dot slot punch 1 16 17
TOOLS INSTRUMENTS &GENERAL SHOP OUTFIT PERUNIT
19 Rule steel 30 cm to read metric 420 Rule steel 60 cm 421 Straight edge 45 cm steel 222 Flate surface 45 cm *45 cm 223 Marking table 91*91*122 cm 124 Universal scribing block 22 cm 225 Block-vee pair 7 cm 15 cm with
clamps2
26 Square adjustable 15cm blade 227 Angle plate 10*20 cm 228 Level sprit 15 cm metal 129 Punch letter 3mm set 130 Punch number set 3mm 131 Punch hillow 6mm to 19 set of 5 232 Punch round 3mm*4mm set of 2 233 Portable hand drill 0to 6 mm 234 Drill brace hand 0to12 mm 235 Drill twist s/s 1.5 to 12 mmby 0.4 mm 1set36 Drill twist s/s 8mm to 15 mmby
1/2mm1set
37 Brace ratchet with pillar 138 Tapes and dies complete set in box
B.A1
39 Tapes and dies complete set in boxB.S.F>
1
40 Tapes and dies complete set in boxWhite-Worth
1
41 Tapes, dies complete set in boxAmerican
1
42 Tapes and dies complete set in box 143 File warding 15 cm smooth 444 File knife edge 15 cm amooth 445 File cut saw 15 cm smooth 446 File feather 15 cm smooth 447 File triangular 15 cm smooth 248 File round 20 cm second cut 849 File round 15 cm second cut 450 File square 25 cm second cut 451 Feeler gauge 10 blades 1 set52 File triangular 20 cm second cut 8
53 File flat 30 cm second cut 854 File flat 20 cm bastard 855 File flat 30 cm bastard 856 File swiss type needle set of 12 2 set57 File half round 25 cm second cut 858 File half round cm bastard 459 File round 30 cm bastard 460 File hand 15 cm second cut 861 Card file 862 Stone oil 15 cm *5 cm*2.5cm 463 Stone carborandam 15 cm*5cm*5cm
*4cm2
64 Can oil 0.25 litres 265 Plier combination 15 cm 266 Iron soldering 350gm. 267 Lamp blow 0.55 liters 268 Spanner white –worth D.E. 6 mm.to
25 mm set of8
69 Spanner adjustable 15 cm 270 Interchangeable 15 cm 271 “Apollo” box spanner set in mm 3*4,
6*7,9*11,12*14,15*19,22*25,set of 62
72 Glass magnifying 7 cm 273 Clamp tool maker 5 cmm and 7.5cm
set of 22
74 Clamp “c” 5 cm 275 Clamp “C” 10 cm 276 Reamer adjustable max. 9 mm 12
mm,19 mm-set of 31set
77 Reamer taper 4mm to 9mm set of 4 178 Reamer parallel 16mm to 12 mm set
of 51
79 Scraper flat 15 cm 880 Scraper 3 corner 15 cm 881 Scraper half round 15 cm 882 Chisel cold 9 mm cross cut 9mm
diamond8each
83 Chisel cold 19 mm flat 884 Chisel cold 9 mm round noze. 885 Extractor stud EZY-out. 286 Set combination 30cm. 287 Micrometer 0-2.5cm outside. 388 Micrometer25-50 mm outside. 389 Micrometer 0-25mm outside 490 Micrometer 50-75mm outside 291 Micrometer inside 25 mm to50mm
Size).112 Metal rack 182*182*4.5cm 1113 Desk. 1114 Stool. 1115 Black board witheasel. 1116 Fire extinguisher(for 4 units) 2117 Fire buckets. 2118 Machines vice. 2119 Wing compass 25.4cm orl 30cm 2120 Hand hammer 1kg. with handle. 2
Tools for Allied Trade-Blacksmithy &Sheet Metal Work
121 Hammer smith 2kg. with handle. 2122 Tongs round. 2123 Tong flat. 1124 Smith’s square 45cm*30cm 1125 Cold set rodded. 2126 Hot set rodded. 1127 Swages top & bottom 12mm\19
Mm,25mm(pait).1
128 Swage block 35*35*12cm. 1129 Flatters(rodded)55 mm square. 2
130 Fuller top & bottom 6 mm, 9 mm(pair).
2
131 Anvil 50 kg. 2132 Anvil Stand. 2133 Shovel. 2
134 Trammer. 1135 Rake, 2136 Quenching tank. 1 (To be
made intheInstitute).
137 Pocker. 2138 Hardle. 2139 Leather apron. 2140 Prick punch. 2141 Mallet. 2142 Snips straight 25 cm. 2143 Setting hammer with handle. 2144 Planishing hammer. 2145 Snip bent 25 cm. 2146 Stake hatchet. 2147 Stakemgrooving. 2148 Gauge imperial sheet. 1General Machinery Installation1 Anvil 50 kg. on stand. 12 Drilling machine pillar sensitive
0-20 mm cap with swivel tablemotorized with chuck & key.
1
3 Drilling machine bench sensitive 0-12mm cap motorized with chuck andkey.
2
4 Forge portable hand blower 38 cm to45 cm.
1
5 Grinding machine (General purpose)D.E.Pedestal with 20 cm dia. Drill grindingattachment.
1
Note1. No additional items of the above list are required to be provided for a batch
of 16 trainees working in the second shift except the item under “TraineesTool Kit and Lockers.”
2 No additional number of items(*) market are required to be provided upto four batches of trainees (i.e.two batchesin the first shift and two in the second shift).3 Drilling machine (Bench Type) one additional number is require to be providedfor each additional batches i.e , in the 1st and 2nd shift.
The specifications of the items in the above list have been given in Metric Units.The items which are available in the market nearest of the specification asmentioned above , if not available as prescribed should be procured. Measuringinstruments such as steel rule which are graduated both English and Metric Unitsmay be procured, if available.
MODIFIED LIST OF TOOLS FOR
THE 2ND YEAR FOR FITTER TRADE[vide letter no. DGET-21 (1)/88 – CD Dtd. 5.7.88 ].
1. Gauge slip as Johnson metric set. 1 set2. Carbide Wear Block 1 mm-2mm. 2 each3. Gauge snap go and no go 25 to 50 mm by 5 mm. 1 set4. Gauge plug single 3 ended 5 to 55 by 1 mm. 1 set5. Gauge telescopic 16. Dial test indicator .01 mm on stand 17. Sine bar 125 mm. 18. Sine bar 250 mm. 19. Lathe tools H.S.S. tipped set 210. Lathe tools bit 6 mm * 75mm. 1211. Lathe tools bit 7 mm * 75mm 1212. Lathe tools bit 9 mm * 85mm 1213. Arm strong type tool bit holder R.H. 214. Arm strong type tool bit holder L.H 215. Arm strong type tool bit holder straight 216. Stilson wrenches 20 cm. 217. Spanner monkey upto 5 cm. 218. Pipe cutter 6 mm to 50 mm wheel type 119. Pipe face to grip pipe upto 50 mm. 220. Pipe stock and dies complete with stocks, bushing, holders, tap 1 set
and tap wrenches sizes covered 6 mm, 9mm, 12mm,19mm,25mm,32mm, 38mm, 50mm.
21 Pipe bender spool type with stand manually operated 122 Adjustable spanner 38 cm long. 123. Adjustable pipe chain tonge 22 cm long to take pipes from 1
3 cm to 63 cm24. Dial vernier caliper 0-130 mm L.C.O. 0.05 mm (Universal Type) 125. Screw thread micrometer with interchangeable 0.4-1.75 mm. 1
Pitch anvils for checking metric threads 60.26. Depth micrometer 0-100 mm 0.01 mm 127. Vernier caliper with thumb block 0-130 mm L.C.O. 0.2 mm 128. Comparator stand with dial indicator 129. Engineer’s try square (Knife-wedge). 130 Surface roughness comparison plates “Roberts”. 1 set
General Machinery Installation*1. Electric Furnace with Capacity 600c 1 No
To 1400 c.2. Lathe all geared head stock S.S. and S.C. height of centre over 2 Nos.
Bed 15 cm-gap head compete with accessories e.g. pump, all fittingsAnd splash guard driver plate with drives; face plate 3 jaw and 4 jawsChucks fixed and traveling steady compound turret tool post, taperTurning attachment, fixed and running centers, driving dogs straightAnd bent tails.
Note: * No additional number of items are requires to be provided up to four batches oftrainees i.e. two batches in the shift an d two in the shift.
• Only one number need be provided in each I.T.I. respecting No. of Units.
LIST OF ISI BOOKS FOR REFERANCE FITTER TRADE
(For use of Instructors only)______________________________________________________________________________SL. No. Titles Codes
1 2 3___________________________________________________________________________1. Spring calipers. IS: 4052 – 19672. Punches IS: 413 - 19743. Metric steel scales for Engineers. IS: 1481 – 19704. Engineers square edges. IS: 2013 – 19725. V-Block. IS: 2049 -19746. Steel straight edges. IS: 2220 – 19627. Hacksaw blades. IS: 2504 – 19778. Bench vices ARE: 2586 – 19759. Chisels (Cold) IS: 402 – 197410. Engineer’s file. IS: 1931 – 197211. Surface plates (C.I.) IS: 2285 – 197412 Twist drills. IS: 5100 – 196013. Vernier depth gauges. IS: 4213 -196714. External micrometers. IS: 2967 -196415. Dimensions for counter-sinks & counter bores. IS: 3406 – 197516. Internal micrometers. IS: 2966 – 196417. Vernier calipers. IS: 3651 – 197418. Vernier height gauges IS: 2021 -196419. Gib-head keys and key ways ARE: 2203 – 197420. Tapper keys and key ways ARE: 2292 – 197421. Screw drivers IS: 884 – 197222. Bevel protractor IS: 4229 -197023. Reamers. IS: 1836 -196124. Thread cutting dies. IS: 1859 -196125. Metric screw threads (Metric thread pitch-gauges) IS: 4211 -196726. Dial gauges. IS: 2092 -196227. Hexagonal bolts and nuts. IS: 2038 – 196828. Feeler gauges (mm. ranges). IS: 3179 – 197629. Spanners, open jaw IS: 2028 – 196830. Thickness of sheet & diameters of wire. IS: 1137 – 195031. Centre drills IS: 6703 – 1977
to 671032. Lathe, sizes for general purpose IS: 2392 – 1963
33. Recommendations for tapping drill sizes. IS: 3230 – 197034. Needle files. IS: 3152 – 196535. Plain plug gauges. IS: 6137 – 1971
To 163836. Plain ring gauges (G0). IS: 3435 – 197337. Snap gauges (Go & No Go) IS: 3477 197338. Slip gauges IS: 2984 – 196639. Ball & roller bearings gauging practice for IS: 4025 – 196740 V-belt for Industrial purposes. IS: 2404 -197441. Limits & fits for engineering, recommendations for IS: 919 – 196342. Plain limit gauges tolerances for. IS: 3455 – 197143 Rivets for general purposes. IS: 2155 – 1961
1921 – 196144 Tapers for general engineering purposes. IS: 3458 – 194445 General Engineering Drawing. IS: 696 - 1972
List of Additional Tools for Allied Trade in Weldin1
1. Transformer welding set 300 amps- continuous 1 setWelding current, with all accessories and electrode holder.
2. Welding cable to carry 400 amps with flexible rubber cover. 50 meter
3. Lugs for cable. 12 Nos.
4. Earth clamps. 2 Nos.
5. Arc welding table (all metal top) 122 cm: 12 cm: 60 cm positioned. 1 No.
6. Oxy-acetylene gas welding set equipment with hoses, regulator and theiraccessories.
Note: Those additional items are to be proviede4 for the Allied TradeTraining where the welding trade does not exist.
SYLLABUS FOR RELATED INSTRUCTIONS
3rd Year
Related instructions should be imparted to all the apprentices during the entireperiod of training including basic training . The subject to be taught to the apprenticesin related instructions:
(1) Trade Theory 3 Weeks or 105hrs.(2) W/S Cal. & Sc. 2 Weeks or 70hrs.(3) Engg. Drawings. 2 Weeks or 70hrs.(4) Social Studies 1 Weeks or 35hrs.
-------------------------------------Total = 8 Weeks or 280hrs
-------------------------------------
Trade Theory
1st Weeks: Safety work-accident their causes : General safety rules and apprentices in aworkshop : Safe working devices, guards, attachment etc. ;
Machine tools and operative-Constructional features,types,functions, and usesof Lathe, drilling m/c, Shaping m/c,grinding m/c and their care andimmanence.
Common Turing operative, cutting spear and feeds, cutting tools-it’sdifferent angles ;Chucks and checking ; Threads and threading-use of accident ;gear boxes and drives .
Common drilling, boring and reaming operations-its tools and materials, speedand feet’s ; different drilling techniques.
Description of grinding machines-surface grinder, portablegrinder and pedestal grinder Common grinding operation.
Common shaping operations tools-it’s materials speed and feed ;different work holding
Methods.
Limits fits and interchangeability ; Definitions of interchangeability and it necessity in Engg.
Field.
Terms of limits as per IS : 91-1963. Definition, types of limit, basicsize, deviation, high and low limit.
Method of expressing tolerance as per IS, tolerance, zero,Clearance and Interference
(Max. min. and mean).
Fits : Definition, types, descriptions of each with sketches. Systemof limit – Hole and shaft basic .
Simple, problems on limit-Fits using relevant I.S.I.
2nd Week : Heat treatment of metal- annealing, tempering, normalizing andcase hardening of mild steel
components. Heat treatment of cutting tools. Changes, in theproperties of material due to effects.
Jointing and Fastening devices-permanent, semi-permanent andTemporary Fasteners of different types and their functions-Bolts,nuts, rivets, studs, pins, cotters, keys,Screws, tapers. Etc.
Power transmission & Drives- Belts and belting-its types, size anduse of belts ; belt fastener, speed parallel and crow- drives Use ofcommercial belt dressing resins, creep and slip calculation for thesize of the new belt.
Toothed gear and gearing-type and of spur, helical, bevel ,herringbone, spiral bevel gearing Rack and pinion, and worm for variouspurpose devices.
Chains and sprockets-description types, uses and method offixing.
Mechanical, hydraulic and pneumatic drives-base principles.
Prime movers-Lines shaft drive system and self drive system.Different drives- reciprocating, reverse, eccentric, crank, cam,rotary to liner and vice-versa.
System of speed variation using stepped pulleys, gear box,disconnect-speed control( Electrically and hydraulically).
Bearing-necessity and classification, description of each. Ballbearing single row and double row-description and advantage.Roller and needle bearing- type and description of each.
Lubrication and lubricants-necessity and types of lubricants,semi-liquid and solid, properties of lubricants-viscosity, oiliness,sp. Gravity, flash point, fire points, freezing point; qualities of good lubricants and importance of correct use oflubricants and their commercial names.
System of lubrication-gravity feed, force feed, splash method etc.
3rd Week : Inspection-need of inspection, types of inspection, stage inspection,routine inspection, final inspection. Types of instruments andequipments.
Introduction to work simplifications related to the trade-jobstudy, job analysis , planning ofSequence of operations.
Maintenance-it’s importance in productivity, safety, service life oftools/equipments ;
General maintenance work-cleaning, lubrication, adjustments ofparts, repairing, inspection/testing, overhauling and painting ;system of maintenance-routine, preventive, breakdown, details ofdaily maintenance-daily, weekly.
Material Handling-different types of appliances and tackle forshifting Loading and unloading of machine and equipment.
Screw-jack-use and working principle.
Chain pulley blocks-use and working principle.
Cranes and hoists for lifting purposes-working principle andmain constructional features.
Working principle and use of other tackles like crab wrenches,slings, rollers, bars and levers.
Special precautions in the handling of heavy equipments, removaland replacement of heavy parts.
Quality and finish of work –Surface finish-necessity-degree ofsurface finish symbol and its numerical value, method of surfacefinish processes such as lapping, honing, buffing.
Protection of finished surface- like pickling, oxidizingelectroplating, galvanizing, metal spraying, metallization andanodizing.
WORKSHOP CALCULATION & SCIENCE
1st Week : Revision and further problem in relation to trade.
Problem on menstruations, work , power and energy.
