THE BENCH WORK TOOLS AND ITS USES

2.1 Introduction
Bench work has its own essential position in all engineering works. In the mechanized
workshops, where most of the work is carried out on an automatic machine, while bench
work has its own importance. The jobs can be finished to a fairly good degree of
accuracy through machining operation; they often require the hand operations to be
done on them to finish to the desired accuracy. A fitter’s work is unavoidable when
different parts are to be assembled in position after they have been finished. Alignment
of machine parts, bearings, engine slide valves and similar other works call for a fitter’s
work. Reconditioning and refitting of machines and machine parts cannot be done
without a skilled fitter. All the above types of works require the use of a large number
of hand tools and a fitter must have good working knowledge of all these tools and
instruments.

2.2 Filter’s vices

Vices are the most suitable and widely used tools for gripping different jobs in position
during various operations carried out in a fitting shop.

There are a fairly good number of different types of vices such as parallel jaw vice,
machine vice, hand vice and pipe vice.

From these, the parallel jaw vice is the most commonly used in general fitting work.
These vices are available in different trade sizes and the selection of a suitable size will
depend upon the maximum size of the work. The width of the jaws determines the size
of the vice.

In fixing it on the fitter’s bench it is held with the help of bolts passing through the
planks of the bench. The bolts are tightened by means of nuts and the vice is held firmly
on the bench. The jaws of the vice are usually kept overhanging the edge of the bench.

2.2.1 Bench vice

It is the most commonly used vice sometimes also known as parallel jaw vice. It
essentially consists of a cast steel body, a movable jaw, a fixed jaw, both made of cast
steel, a handle, a square threaded screw and a nut all made of mild steel. A separate cast
steel plates known as jaw plates with teeth are fixed to the jaws by means of set screws
and they can be replaced when worn. The movement of the vice is caused by the screw
which passes through the nut fixed under the movable jaw. The screw is provided with
a collar inside to prevent it from coming out and handle at the outer end. The width of
the jaws suitable for common work varies from 80 to 140 mm and the maximum
opening being 95 to 180 mm.

Fig. 2.1 Bench vice

2.3 Surface Plate
Its specific use is in testing the trueness of a finished surface, testing a try square,
providing adequate bearing surface for V-block and angle plates, etc., in scribing work.

It is a cast iron plate having a square or rectangular top perfectly planed true and square
with adjacent machined faces. The top is finished true by means of grinding and
scrapping. This plate carries a cast iron base under it and the bottom surface of the base
is also machined true to keep the top surface of the plate in a perfect horizontal plane.
 Fig. 2.2 Surface plate
2.4 ‘V’ –Block
A ‘V” block serves as a very useful support to the work in marking. It usually works in
conjunction with a U-clamp.

Round bar is placed longitudinally in the block and the screw in the clamp tightened.
Its specific use is in holding the round bars during marking and center drilling their end
faces, which are to be held between centers on the lathe. Also it is very suitable for
holding round bars in drilling operations when the axis of the drill is to be kept normal
to the axis of the bar.
 Fig. 2.3 V-Block
2.5 Simple Scribing Block

It is principal marking tool in a fitting shop and is made in various forms and sizes. It
consists of a cast iron sliding base fitted with a vertical steel rod. The marker is fitted
into an adjustable device carrying a knurled nut at one end. By means of the nut the
marker can be loosened or tightened to set it at any desired inclination, moved to and
fro inside the hole accommodating it or adjust its height along the vertical pillar.
Normally it is used in conjunction with either a surface plate or marking table. Its
specific use is in locating centers of round rods held in V-block, describing straight lines
on work held firmly in its position by means of a suitable device like angle plate and
also in drawing a number of lines parallel to a true surface.

2.6 Universal Surface Gauge

It consists of a cast base, perfectly planed at the top, bottom and all sides. Two guide
pins are provided at the rear end of the base which can be pressed down to project below
the base. These pins can be used against the edge of the surface plate or any other
finished surface for guiding the instrument during scribing.

A swivel bolt is provided at the top of the base in which the spindle is fitted. This spindle
can be swung and locked in any desired position by means of the adjusting screw. The
scriber is fitted in an adjustable screw on the spindle and is capable of being adjusted at
any inclination and height along the spindle. A rocker is provided at the top of the base
and it carries an adjusting screw at its rear end.
 Fig. 2.4 Simple scribing block and universal surface gauge
2.7 Try Square

It is better known as engineer’s try square and is a very common tool used for scribing
straight lines at right angles to a true surface or testing the trueness of mutually normal
surfaces. They are made in different sizes from the steel pieces.
 Fig. 2.5 Try square
It consists of a steel blade fitted into a steel stock of rectangular cross-section. They are
well hardened and tempered to suit the need. Both inner and outer surface of the blade
are kept truly at right angles to the corresponding surfaces of the stock.
2.8 Bevel Gauge

Whenever angles other than right angles are required to be tested or set and marked
sliding bevel square or bevel gauge is used.

It consists of a steel stock of rectangular cross-section carrying a slotted steel blade at

its end. This blade can be made to slide, set at any desired angle and secured in that
position by means of a screw.

2.9 Files
Files of different types are the principal hand tools used by a fitter. All the files,
irrespective of their shape, size and grade, essentially consist of two main parts, viz., a
toothed blade and a pointed tang, which is fitted in a handle. Files are generally forged
out of high carbon steel, followed by cutting of teeth, hardening and tempering etc.
Common shapes of the files available are flat, hand, square, pillar, round, half round,
triangular, knife edge, etc.

These files are manufactured in different varieties and their classification is governed
by the following factors: effective length- i.e. excluding the length of tang, shape or
form of the cross-section, depth, spacing and cut of teeth

Length of the files varies according to the need but the most commonly used lengths
range from 10 cm to 30 cm and they cover almost all sorts of filing work done by hand.

Length between 10 cm and 15 cm are generally used for fine work, between 15 cm and
25 cm for medium sized work and above 25 cm for all general and large sized jobs.

Square file which carried double cut teeth on all the four faces and is normally made
tapered for about one-third of its length near the end opposite to the tang.

Triangular file which normally carries single cut teeth on all the faces and is made
tapered towards the end for about two-third of its length near the tip. The cross-section
is an equilateral triangle.
 Fig. 2.6 Types of files
Teeth of the files may single cut or double cut. Single teeth are parallel and at angle of
60ºto the center line of the file. Double cut files have two sets of teeth, the overcut
teeth are cut at angle of 60º and the uppercut at 75º to 80º to the centre line. Files are
also further classified according to the coarseness or spacing between the rows of
teeth.

1. Rough (R) with 10 to 4.5 cuts per 10 mm length

2. Bastard (B) with 18 to 6 cuts per 10 mm length
3. Second cut (SC) with 21 to 11 cuts per 10 mm length
4. Smooth (S) with 30 to 15 cuts per 10 mm length
5. Dead smooth (DS) with 35 to 28 cuts per 10 mm length
6. Super smooth (SS) with 63 to 40 cuts per 10 mm length
2.10 Scrapers
Scraping is a very important hand operation in bench work employed for obtaining a
fine surface finish on the work, particularly for removing convex spots from machined
surfaces, and the tools used for doing this operation are known as scrapers.

They vary in shape and size, depending upon the specific work for which they are
employed.

They are usually made from rejected old files. Such files are heated and bent to the
desired shape. They are fitted with a wooden handle.

2.11 Chisels

There are many verities of chisels used for chipping work by a fitter. Some very
commonly used forms are Flat, Cross-cut, Round nose and Diamond point.

All the chisels are forged from bar stock of carbon steel, to the desired shape and the
cutting edge ground to the correct angle.

The forging operation is followed by annealing, hardening and tempering to make chisel
body tough and obtain a sharp cutting edge.

Full length of the chisel is never hardened, only a small length about the cutting edge
(say about 20 to 30 mm) is hardened.

The included angle at the cutting edge varies between 40 and 70, depending upon the
material on which it is to be used. Approximate values of cutting angles for common
materials are as follows:

Brass and copper 40

Wrought iron 50

Cast iron and general cutting work 60

Steel (cast) 70

A flat chisel is a general purpose chisel which is most widely used in cutting work,
chipping large surface, cutting metal sheets, rods, bar stocks and similar other purposes.
Since it cuts the metal in cold state it is also frequently known as cold chisel.
A round nose chisel is used for drawing the eccentric hold back to the correct center
which has run off-center during the drilling operation. Another specific use of this type
of chisel is in cutting oil grooves and channels in bearings and pulley bushes and
cleaning small round corners.

A cross cut is a comparatively narrow chisel having its cutting edge slightly broader
than the blade. It is made to keep the blade free when the chisel is used to cut deep
groove into the metal. Normal widths of the cutting edge vary from 3 mm to 12 mm.
This chisel is used to cut parallel grooves on large surfaces, before chipping by means
of a flat chisel, cutting key ways, etc.

A diamond point chisel is a special purpose chisel used for chipping rough plates and
cutting cast iron pipes, cutting ‘V’ grooves, chipping sharp corners, squaring up corners
of previously cut slots and cleaning angles.
 Fig. 2.7 Types of chisel
2.12 Hammers

The hammer is one of the most widely used fitter’s tools. It is used for striking chisels
in chipping and cutting and the punch in marking.

All the hammers used in a fitting shop are similar in construction to the smith’s hand
hammers, such as ball peen, cross peen, straight peen, etc. The only difference lies in
weight. Hammers used in fitting work are comparatively lighter in weight than the
smith’s hand hammers. They normally weigh from 0.45 kg to 0.7 kg.
Ball peen hammer is the most commonly used hammer. The peen is ball shaped. It is
used for riveting, chipping, drawing and laying out. The weight of the hammer varies
from 0.11 to 0.91 kg (as per IS standards)..

Fig. 2.8 Hammers

Cross peen hammer resembles the ball peen hammer in shape except that its peen is in
wedge shape and at right angles to the eye. This hammer is used for bending and
hammering in the corners.

Straight peen hammer has a peen in line with the handle and is used for peening or
stretching the metal.

2.13 Hack-Saw
Desired lengths of bar stocks, rods, tubes, iron flats and metal sheets, etc. are always
required to be cut in fitting shop. Hack-saw is a common tool used for this purpose. It
consists of a metal frame, fitted with a wooden handle, carrying metal clips with wing-
nut at its end to hold. The clip carrying the wing nut is threaded so as to stretch the blade
to the desired extent. The frame can be either of fixed type, which can accommodate
the same length of blades or adjustable type which is capable of accommodating
different lengths of blades.

Hack saw blades are made of high carbon steel or low alloy steel. Hack saw blade is the
main part. Push type blades, those which cut in forward stroke only, are generally used.
In these, the teeth always point away from the operator. The blades in common use are
generally 0.7 mm thick, 12.7 mm wide and 20 cm to 30 long. About 5 to 7 teeth per cm
length of blade from the course group and 8 to 12 teeth per cm from the fine group of
teeth.

Fig. 2.9 Different parts of a hack saw

3.1 Miscellaneous Tools

1. Punch

A punch made from a steel rod with a length of 90 to 150 mm and a diameter of 8 to 13
mm is used in bench work for marking purpose and locating centres in more permanent
manner. The punch with a tapered point angle of 400 is called a princk punch and that
of600 point angle is called a centre punch.
 Fig. 3.1 Punch

2. Calipers

Calipers are the devices used for measuring and transferring the inside or outside
dimensions of components. Although gradually they are being replaced by the more
accurate and precision instruments and gauges, like micrometers in modern workshops,
still they stand as the in general work on account of their cheapness and ease in
handling.

3. Screw Drivers

It is a very useful hand tool for rotating the screws. It consists of wooden or a plastic
handle and steel blade, shaped at the end. The flat end of the tool is inserted into the
slot provided on the head of the screw for rotating it. Screw drivers are made in various
sizes to suit the corresponding sizes of the slots on the screw heads. Sometimes star
headed screw driver is used for star headed screws.
 Fig. 3.2 Screw driver
4. Drills
Drilling is an important operation carried out in a fitting shop for producing different
types and sizes of holes in various materials. There are many forms of drills used for
this purpose.

The simplest form is a flat drill which is used for wood work. The other important and
most widely used is a fluted twist drill. It has a cylindrical body carrying the spiral flutes
cut on its surface. Twist drills are usually made of high-speed steel, some cheaper
varieties are made of high carbon steel. They are made in different forms to suit the
work but the most commonly used types are (i) those having parallel shank and (ii)
those having tapered shank,Parallel shank is provided on small sized drills (say up to
12.7 mm) only and those above this size are usually provided with a tapered shank.

The twist drill essentially consists of two main parts, a shank which is gripped in the
chuck of the drilling machine and the body forms the main cutting unit. Main
advantages of using twist drills are:

1. The chips of the metal are automatically driven out of the hole through the spiral
flutes.
2. Cutting edges are retained in good condition for a fairly long period.

3. Heavier feeds and speeds can be quite safely employed.

4. For the same size and depth of hole they need less power as compared to other
forms of drills.
 Fig. 3.3 Twist drill
5. Taps
The hand operated taps used in fitting shops are employed for cutting internal threads
in cylindrical holes or for cleaning damaged threads in similar parts. A tap consists of
a toothed body having flutes (usually 4) cut on its surface, a round shank and a square
formation at the end of the shank. The flutes are provided for the same purpose as in
case of a twist drill and square formation at the top enables to grip by the tapping handle.

All the hand taps of different sizes are usually available in a set of three taps of each
size known as taper or rough, second and finish or plug respectively. The main
difference between the three taps is the chamfer angle. In the threading operations they
are used in the same order as taper, second and plug.

When starting tapping care should be taken to start the thread in alignment with the
hole. Also the tap should be occasionally rotated back about a turn to break the chips
and facilitate their removal.

Fig. 3.4 Taps and tap wrench

6. Dies and stocks
Dies are used to cut threads on a round bar of a metal, such as the threads on a bolt. It
is a round or square block of hardened steel with a hole containing threads and flutes
which form cutting edges. Die may be a solid or adjustable type. Solid die has fixed
dimensions. An adjustable die may be split type with a split through one side or two
piece rectangular type. These types of dies are fitted into special stocks and closed by
means of adjusting screws.The size of a die is specified by the outside diameter of the
thread to be cut and pitch of the thread.

Fig. 3.5 Die and die handles

3.2 Bench Work Processes

Bench work involves following hand operations to finish the work to desired shape and
size with required accuracy.

1. Marking

2.Chipping
 3.Sawing

4. Filing

5. Draw filing

6.Threading

7. Grinding

Some common bench work processes are described here

1. Marking

 It is the basic and one of the most important operations in bench work.
 It should be remembered that how accurately and carefully one tries to perform
other operations it will be of no help until and unless the piece has been properly
and accurately marked.
 Sufficient care should be exercised in performing this operation to obtain a
desired fitting of the components.
 Marking on the work can be done by setting out dimensions with the help of a
working drawing.
 The surface to be marked is coated with either the paste of red lead or chalk and
allowed to dry.
 After that, the work is held in a clamp, if it is round. If the work is too thin, it is
normally supported against an angle plate keeping the surface to be marked in a
vertical plane. Lines in horizontal direction are scribed by means of a scribing
gauge.
 Lines at right angles to this can be drawn easily by first turning the work through
90 and then using the scriber.
 Lines can easily be marked with the help of a try square. Circles and arcs on flat
surfaces are inscribed by means of dividers.
 After the scribing work is over, indentations on the surface are made, by using
the center punch and hammer along the scribed lines and arcs.
 The punch marks serve as the guide during further operations like filing, chipping
and drilling. etc.
2. Chipping
 It is the operation employed for removing the excess metal by means of cold
chisels.
 To have a properly chipped surface it is essential that the same cutting angle
should be maintained throughout the operation.
  In case the surface is too large it is advisable to cut grooves along the whole
surface by means of a cross cut chisel and then chip off the remaining metal.
 The cutting angles of the chisels differ for different metals.
 Frequent lubrication and cooling of the cutting edge, while taking heavy cuts
for removing large amount of metal, it helps considerably in chipping the metal
easily and more effectively.
 To the correct cutting angle of the chisel, proper gripping of the chisel and the
hammer and correct standing position of the operator play a significant part.
 The chisel should be firmly gripped in one hand leaving about 3 to 5 cm length
above the thumb of the hand, and hammer should be held near the end of the
handle to ensure more power in the blows.
 The operator should stand erect with his two feet sufficiently apart to balance
his own weight equally on both the feet.
 The operator should always see the cutting edge of the chisel and not the top of
the same.
3. Sawing

 This operation is performed in fitting shop for cutting different metal pieces to
the desired size and shape, usually prior to other operations such as filing,
drilling, scraping, etc.
 It is also employed for cutting metal pieces of required length out of the bar stock.
 For sawing, the saw blade should be properly fitted, and stretched to have the
proper tension, in such a way that the cutting teeth always point away from the
operator so as to cut the metal in forward stroke.
 Sawing should be done steadily and slowly.
 An average speed of about 50 strokes per minute is a good practice.
 Sufficient pressure should be exerted in the forward stroke and this be relieved
during the backward stroke.
 It is advisable to use a coolant throughout the operation. A new blade should not
be directly used on a hard metal.
4. Filing

 Similar to the saw blades, most of the files have their teeth pointing away from
the operator such that they cut during the forward stroke.
 The pressure of the hand in filing should also be applied only during the forward
stroke and relieved during the return stroke.
 Beginners particularly should be careful enough to practice correct movement of
file.
 It should always be more in a perfect horizontal plane for obtaining a truly plane
and smooth surface.
 As far as possible, try to use full length of the file during the operation.
  Moving the file diagonally on a flat surface always yields best results. A coarse
pitched file should be employed when enough metal is to be removed, followed
by finishing with a smooth file.
5. Draw filing
 When the surface is to be finally finished by filing only and no other operation,
like scraping, is to follow the filing operation, a special method of filing, called
Draw filing, is employed for finishing the surface.
 A flat file of fine cut is used for this operation.
 It should be ensured before use that the file teeth are free from metal particles,
 Otherwise a numbers of scratches will be produced on the surface. It is usual to
employ a file card quite frequently for cleaning the file teeth both before use as
well as during use.
 For draw filing operation the file is held flat on the surface between the two
hands.
 The file must move forward and backward. Flatness and evenness of the surface
should be checked quite frequently during the operation.
For final finishing, it is a common practice to rub a chalk piece over the entire surface
of the file. This helps in producing a finely finished surface.
Fig. 3.6 Cross and draw filing