ITI Fitter Theory Notes

6 lessons13 min

1. 1.1 ITI FamiliarisationWhat an ITI is, how the Fitter course runs, who is who in the institute and what you can do after it. 2 min
2. 1.2 Safety Precautions in the WorkshopAccidents do not happen, they are caused. General, personal and machine safety rules every fitter must follow. 3 min
3. 1.3 Personal Protective Equipment (PPE)Types of PPE, which hazard each protects from and how to choose and care for it. 2 min
4. 1.4 Safety Signs and Fire SafetyColours and shapes of safety signs, classes of fire and the right extinguisher for each. 2 min
5. 1.5 Housekeeping, 5S and Waste DisposalKeeping the workshop clean and organised with 5S, and disposing of shop waste safely. 2 min
6. 1.6 Hot Work and Safe LiftingPrecautions for welding, grinding and cutting, and the correct way to lift and carry loads. 2 min

9 lessons19 min

1. 2.1 Linear Measurement and the Steel RuleUnits of length, the engineer's steel rule and how to read it without parallax error. 2 min
2. 2.2 Calipers and DividerOutside, inside and odd-leg calipers and the divider – what each one measures or marks. 2 min
3. 2.3 Marking Tools: Punches, Marking Media, Surface Plate, Angle Plate, V-BlockTools and surfaces used to mark out a job accurately before cutting. 2 min
4. 2.4 Bench Vice and HacksawParts and use of the bench vice; hacksaw frame, blade pitch and correct sawing method. 3 min
5. 2.5 FilesParts, cuts, grades and shapes of files, and how to choose the right file. 2 min
6. 2.6 Try Square and Cold ChiselChecking squareness with a try square; types and point angles of cold chisels and safe chipping. 2 min
7. 2.7 Vernier CaliperPrinciple, parts and least count (0.02 mm) of the vernier caliper, with a reading example. 2 min
8. 2.8 Outside MicrometerPrinciple, parts and least count (0.01 mm) of the outside micrometer, reading and precautions. 2 min
9. 2.9 Properties of MetalsPhysical and mechanical properties of metals and why a fitter must know them. 2 min

4 lessons8 min

1. 3.1 Sheet Metal Safety and ToolsSafety in sheet metal work, snips, hand lever shears, mallets, hammers and stakes. 2 min
2. 3.2 Seams and EdgesGrooved, locked, lap seams; wired edge and hem – how sheet metal parts are joined and stiffened. 2 min
3. 3.3 SolderingSoft solder, flux and the soldering process for joining sheet metal. 2 min
4. 3.4 RivetingTypes of rivet heads, riveting process, rivet length, pitch and edge distance. 2 min

5 lessons11 min

1. 4.1 Welding SafetyHazards of welding and gas cutting, and the protective equipment and precautions against them. 2 min
2. 4.2 Arc Welding ParametersWelding current, arc length, travel speed, electrode angle and polarity in manual metal arc welding. 2 min
3. 4.3 CO₂ / MIG WeldingPrinciple, equipment and advantages of gas metal arc (CO₂/MIG) welding. 2 min
4. 4.4 Oxy-Acetylene Gas CuttingCylinders, regulators, flashback arrestor, types of flame and the gas cutting process. 3 min
5. 4.5 Types of Weld JointsButt, lap, fillet (T), corner and edge joints, and the parts of a weld. 2 min

6 lessons12 min

1. 5.1 Twist Drill – Parts and AnglesParts of a twist drill and its important angles: point angle 118°, lip clearance and helix angle. 2 min
2. 5.2 Cutting Speed, RPM and FeedWhat cutting speed and feed are, and how to calculate drill RPM with the formula. 2 min
3. 5.3 Drill Holding Devices and Drill TroublesDrill chuck, sleeve and socket, drift, and the common drilling troubles with their remedies. 2 min
4. 5.4 Reamers and ReamingWhy holes are reamed, types of reamers, reaming allowance and correct method. 2 min
5. 5.5 Taps and DiesCutting internal threads with taps and external threads with dies; tap drill size. 2 min
6. 5.6 Limit Gauges: Plug, Ring and SnapGO and NO-GO gauges for checking holes and shafts quickly in production. 2 min

5 lessons11 min

1. 6.1 Interchangeability: Limits, Fits and ToleranceBasic size, limits, tolerance, allowance, types of fit and the hole basis system. 2 min
2. 6.2 Engineering Metals: Cast Iron, Steel and Non-ferrous MetalsFerrous and non-ferrous metals used in fitting, with their properties and uses. 2 min
3. 6.3 ScrapingWhy surfaces are scraped, types of scrapers, blue matching and bearing marks. 2 min
4. 6.4 Precision Instruments: Vernier Micrometer, Screw Thread Micrometer, Dial Test IndicatorInstruments for 0.001 mm readings, measuring thread pitch diameter and checking with a DTI. 2 min
5. 6.5 Fitting Jobs: Sliding, Angular, Step, T and Square FitsCommon fitting assignments of the first year and how to make them to ±0.04 mm accuracy. 3 min

5 lessons12 min

1. 7.1 Centre Lathe – Parts and FunctionsBed, headstock, tailstock, carriage and feed mechanism of the centre lathe. 2 min
2. 7.2 Lathe Safety and Work HoldingSafety on the lathe, holding work between centres with driving dog and catch plate, and chucks. 3 min
3. 7.3 Single Point Cutting Tool and Tool AnglesTool materials, rake and clearance angles and why each angle is needed. 2 min
4. 7.4 Lathe OperationsFacing, plain and step turning, knurling, taper turning and external thread cutting. 3 min
5. 7.5 Cutting Speed, Feed, Depth of Cut and Coolants on the LatheChoosing spindle speed, feed and depth of cut, and the purpose and types of coolants. 2 min

4 lessons9 min

1. 8.1 Total Productive Maintenance (TPM)Aim of TPM, its pillars and the six big losses – maintenance with the involvement of every worker. 2 min
2. 8.2 Routine and Preventive MaintenanceDaily routine care, preventive (scheduled) maintenance and breakdown maintenance compared. 2 min
3. 8.3 Inspection and LubricationTypes of inspection, simple inspection gadgets, and lubricants and lubrication methods. 2 min
4. 8.4 Installation, Overhauling, Assembly Techniques and Dowel PinsInstalling a machine on its foundation, overhauling, good assembly practice and the use of dowel pins. 3 min