FITTER-(TRADE THEORY)

SECOND YEAR

1. Make & assemble components of different mating surfaces as per required

WEEK NO: 1
 Screws: material, designation, specifications, Property classes (e.g. 9.8 on screw head),
 Tools for tightening/ loosening of screw or bolts,
 Torque wrench, screw joint calculation uses.
 Power tools: its constructional features, uses & maintenance.
WEEK NO: 2
 Locking device: Nuts- types (lock nut castle nut, slotted nuts, swam nut, grooved nut)
 Description and use. Various types of keys, allowable clearances.
 Tapers, types, uses of key pullers.
WEEK NO: 3
 Special files: types (pillar, Dread naught, Barrow, warding) description & their uses.
WEEK NO: 4
 Templates and Radius/fillet gauge, feeler gauge, hole gauge, and their uses, care and maintenance.
WEEK NO: 5
 Slip gauge: Necessity of using, classification & accuracy, set of blocks (English and Metric).
 Details of slip gauge. Metric sets 46: 103: 112.
 Wringing and building up of slip gauge and care and maintenance.
WEEK NO: 6
 Application of slip gauges for measuring,
 Sine Bar-Principle, application & specification.
 Procedure to check adherence to specification and quality standards.
WEEK NO: 7
 Lapping: Application of lapping, material for lapping tools,
 Lapping abrasives, charging of lapping tool.
 Surface finish importance, equipment for testing-terms relation to surface finish.
 Equipment for tasting surfaces quality – dimensional tolerances of surface finish.
WEEK NO: 8
 Honing: Application of honing, material for honing, tools shapes, grades,
 Honing abrasives. Frosting- its aim and the methods of performance.
WEEK NO: 9
 Metallurgical and metal working processes such as Heat treatment, various heat treatment methods -
normalizing, annealing, hardening and tempering, purpose of each method, tempering colour chart.
WEEK NO: 10
 Annealing and normalizing, Case hardening and carburising and its methods, process of carburising
(solid, liquid and gas).
WEEK NO: 11
 Tapers on keys and cotters permissible by various standards.
WEEK NO: 12
 The various coatings used to protect metals, protection coat by heat and electrical deposit treatments.
 Treatments to provide a pleasing finish such as chromium silver plating, nickel plating and galvanizing.
 2. Make different gauges by using standard tools & equipment and checks for
specified accuracy. [Different Gauges – Snap gauge, Gap gauge; Specified
Accuracy - ±0.02mm]

WEEK NO: 13
 Gauges and types of gauge commonly used in gauging finished product
 Method of selective assembly ‘Go’ system of gauges, hole plug basis of standardization.
WEEK NO: 14
 Bearing-Introduction, classification (Journal and Thrust), Description of each,
 Ball bearing: Single row, double row, description of each, Advantages of double row.
WEEK NO: 15
 Roller and needle bearings: Types of roller bearing. Description & use of each.
 Method of fitting ball and roller bearings
WEEK NO: 16
 Bearing metals – types, composition and uses.
 Synthetic materials for bearing: The plastic laminate materials, their properties
 Uses in bearings such as phenolic, Teflon polyamide (nylon).
WEEK NO: 17
 The importance of keeping the work free from rust and corrosion.
3. Apply a range of skills to execute pipe joints, dismantle and assemble valves
& fittings with pipes and test for leakages. [Range of skills – Cutting,
Threading, Flaring, Bending and Joining]

WEEK NO: 18
 Pipes and pipe fittingcommonly used pipes.
 Pipe schedule and standard sizes. Pipe bending methods.
 Use of bending fixture, pipe threadsStd. Pipe threads Die and Tap pipe vices.
WEEK NO: 19
 Use of tools such as pipe cutters, pipe wrenches,
 pipe dies, and tap, pipe bending machine etc.
WEEK NO: 20
 Standard pipefittingMethods of fitting or replacing the above fitting,
 Repairs and erection on rainwater drainage pipes and household taps and pipe work.
 Inspection & Quality control Basic SPC -Visual Inspection.
4. Make drill jig & produce components on drill machine by using jigs and
check for correctness.

WEEK NO: 21
 Drilling jig-constructional features, types and uses. Fixtures-Constructional features, types and uses.
5. Plan, dismantle, repair and assemble different damaged mechanical
components used for power transmission & check functionality. [Different
Damage Mechanical Components – Pulley, Gear, Keys, Jibs and Shafts.]

WEEK NO: 22
 Aluminum and its alloys.Uses, advantages and disadvantages, weight and strength as compared with
steel.
 Non-ferrous metals such as brass, phosphor bronze, gunmetal, copper, aluminum etc.
 Their composition and purposes, where and why used, advantages for specific purposes,
 Surface wearing properties of bronze and brass.
 WEEK NO: 23
 Power transmission elements.
 The object of belts, their sizes and specifications, materials of which the belts are made,
 Selection of the type of belts with the consideration of weather,
 Load and tension methods of joining leather belts.
WEEK NO: 24
 Vee belts and their advantages and disadvantages,
 Use of commercial belts, dressing and resin creep and slipping, calculation.
 Power transmissionscoupling types-flange coupling,-Hooks couplinguniversal coupling and their
different uses.
WEEK NO: 25
 Pulleys-types-solid, split and ‘V’ belt pulleys, standard calculation for determining size
 Crowning of faces -loose and fast pulleys -jockey pulley. Types of drives -open and cross belt drives.
 The geometrical explanation of the belt drivers at an angle.
WEEK NO: 26
 Clutch: Type, positive clutch (straight tooth type, angular tooth type).
 Chains, wire ropes and clutches for power transmission.
 Their types and brief description.
WEEK NO: 27
 Power transmission –by gears, most common form spur gear,
 Set names of some essential parts of the set -The pitch circles,diametral pitch,
 Velocity ratio of a gear set.
WEEK NO: 28
 Helical gear, herring bone gears, bevel gearing, spiral bevel gearing, hypoid gearing, pinion and rack,
worm gearing,
 Velocity ratio of worm gearing.
 Repair of gear teeth by building up and dovetail method.
WEEK NO: 29
 Method or fixing geared wheels for various purpose drives.
 General cause of the wear and tear of the toothed wheels and their remedies,
 Method of fitting spiral gears, helical gears, bevel gears, worm and worm wheels in relation to
required drive.
 Care and maintenance of gears.
6. Identify, dismantle, replace and assemble different pneumatics and
hydraulics components. [Different components – Compressor, Pressure
Gauge, Filter Regulator Lubricator, Valves and Actuators.] Construct
circuit of pneumatics and hydraulics observing standard operating
procedure& safety aspect.

WEEK NO: 30
 Fluid power, Pneumatics, Hydraulics, and their comparison,
 Overview of a pneumatic system, Boyle’s law.
 Overview of an industrial hydraulic system, Applications, Pascal’s Law.
WEEK NO: 31
 Compressed air generation and conditioning, Air compressors, Pressure regulation,
 Dryers, Air receiver, Conductors and fittings, FRL unit,
 Applications of pneumatics, Hazards & safety precautions in pneumatic systems.
 WEEK NO: 32
 Pneumatic actuators:- Types, Basic operation, Force, Stroke length,
 Single-acting and double-acting cylinders.
7. Identify, dismantle, replace and assemble different pneumatics and
hydraulics components. [Different components – Compressor, Pressure
Gauge, Filter Regulator Lubricator, Valves and Actuators.] Construct
circuit of pneumatics and hydraulics observing standard operating
procedure& safety aspect.

WEEK NO: 33
 Pneumatic valves:- Classification, Symbols of pneumatic components
 3/2- way valves (NO & NC types) (manually-actuated & pneumatically-actuated) & 5/2-way valves,
 Check valves, Flow control valves, One-way flow control valve Pneumatic valves: Roller valve, Shuttle
valve, Twopressure valve Electro-pneumatics:
 Introduction, 3/2-way single solenoid valve, 5/2-way single solenoid valve, 5/2-way double solenoid
valve,
 Control components - Pushbuttons (NO & NC type) and Electromagnetic relay unit, Logic controls.
WEEK NO: 34
 Symbols of hydraulic components, Hydraulic oils –function, properties, and types,
 Contamination in oils and its control - Hydraulic Filters – types, constructional features,
 typical installation locations, cavitation
WEEK NO: 35
 Hazards & safety precautions in hydraulic systems - Hydraulic reservoir & accessories,
 Pumps, Classification – Gear/vane/ piston types, Pressure relief valves – Direct acting and pilot-
operated types
 Pipes, tubing, Hoses and fittings – Constructional details, Minimum bend radius, routing tips for hoses.
WEEK NO: 36
 - Hydraulic cylinders –Types - Hydraulic motors –Types - Hydraulic valves: Classification,
 Directional Control valves – 2/2- and 3/2-way valves - Hydraulic valves: 4/2- and 4/3-way valves,
Centre positions of 4/3-way valves –
 Hydraulic valves: Check valves and Pilot-operated check valves, Load holding function - Flow control
valves:
 Types, Speed control methods – meter-in and meter-out - Preventive maintenance & troubleshooting
of pneumatic & hydraulic systems,
 System malfunctions due to contamination, leakage, friction, improper mountings, cavitation, and
proper sampling of hydraulic oils.
8. Plan & perform basic day to day preventive maintenance, repairing and
check functionality. [Simple Machines – Drill Machine, Power Saw and
Lathe]

WEEK NO: 37
 Importance of Technical English terms used in industry –(in simple definition only)
 Technical forms, process charts, activity logs, in required formats of industry,
 Estimation, cycle time, productivity reports, job cards.
WEEK NO: 38
 Method of lubrication-gravity feed, force (pressure) feed, splash lubrication.
WEEK NO: 39
 Cutting lubricants and coolants: Soluble off soaps, sudsparaffin, soda water,
WEEK NO: 40
 Common lubricating oils and their commercial names, selection of lubricants.
 WEEK NO: 41
 Washers-Types and calculation of washer sizes. The making of joints and fitting packing.
9. Plan, erect simple machine and test machine tool accuracy. [Simple
Machines – Drill Machine, Power Saw and Lathe]

WEEK NO: 42
 Lubrication and lubricantspurpose of using different types, description and uses of each type. Method
of lubrication. A good lubricant, viscosity of the lubricant, Main property of lubricant. How a film of oil
is formed in journal Bearings.
 WEEK NO: 43
 Foundation bolt: types (Lewis cotter bolt) description of each
 Erection tools, pulley block, crowbar, spirit level, Plumb bob, wire rope, manila rope, wooden block.
WEEK NO: 44
 The use of lifting appliances, extractor presses and their use.
 Practical method of obtaining mechanical advantage.
WEEK NO: 45
 The slings and handling of heavy machinery,
 Special precautions in the removal and replacement of heavy parts.