Introduction to Basic Manufacturing Processes and ... - always yours

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5. Back saw 6. Panel saw 7. Miter saw 3. Planning Tools 1. Jack plane 2. Circular plane 3. Router plane 4. Rabbet plane 5. Block plane 6. Bench plane 7. Core box plane 4. Boring Tools Pattern and Core Making 193 1. Hand operated drills 2. Machine operated drills 3. Twist drill 4. Countersunk 5. Brace 6. Auger bit 7. Bit gauge 5. Clamping Tools 1. Bench vice 2. C-clamp 3. Bar clamp 4. Hand screw 5. Pattern maker’s vice 6. Pinch dog 6. Miscellaneous Tools 1. Screw Driver 2. Vaious types of hammers 3. Chisel 4. Rasp 5. File 6. Nail set 7. Screw driver 8. Bradawl 9. Brad pusher 10. Cornering tool 10.11 WOODEN PATTERN AND WOODEN CORE BOX MAKING MACHINES Modern wooden pattern and wooden core making shop requires various wood working machines for quick and mass production of patterns and core boxes. Some of the commonly machines used in making patterns and coreboxes of various kinds of wood are discussed as under. 1. Wood Turning Lathe. Patterns for cylindrical castings are made by this lathe. 2. Abrasive Disc Machine. It is used for shaping or finishing flat surfaces on small pieces of wood. 3. Abrasive Belt Machine. It makes use of an endless abrasive belt. It is used in shaping the patterns. 4. Circular Saw. It is used for ripping, cross cutting, beveling and grooving. 5. Band Saw. It is designed to cut wood by means of an endless metal saw band. 6. Jig or Scroll Saw. It is used for making intricate irregular cuts on small work. 7. Jointer. The jointer planes the wood by the action of the revolving cutter head.
194 Introduction to Basic Manufacturing Processes and Workshop Technology 8. Drill Press. It is used for drilling, boring, mortising, shaping etc. 9. Grinder. It is used for shaping and sharpening the tools. 10. Wood Trimmer. It is used for mitering the moldings accurately. 11. Wood Shaper. It is used for imparting the different shapes to the wood. 12. Wood Planer. Its purpose is similar to jointer but it is specially designed for planning larger size. 13. Tennoner. These are used for sawing (accurate shape and size). 14. Mortiser. It is used to facilitate the cutting of mortise and tenon. 10.12 DESIGN CONSIDERATIONS IN PATTERN MAKING The following considerations should always be kept in mind while designing a pattern. 1. All Abrupt changes in section of the pattern should be avoided as far as possible. 2. Parting line should be selected carefully, so as to allow as small portion of the pattern as far as possible in the cope area 3. The thickness and section of the pattern should be kept as uniform as possible. 4. Sharp corners and edges should be supported by suitable fillets or otherwise rounded of. It will facilitate easy withdrawal of pattern, smooth flow of molten metal and ensure a sound casting. 5. Surfaces of the casting which are specifically required to be perfectly sound and clean should be so designed that they will be molded in the drag because the possible defects due to loose sand and inclusions will occur in the cope. 6. As far as possible, full cores should be used instead of cemented half cores for reducing cost and for accuracy. 7. For mass production, the use of several patterns in a mould with common riser is to be preferred. 8. The pattern should have very good surface finish as it directly affects the corresponding finish of the casting. 9. Shape and size of the casting and that of the core should be carefully considered to decide the size and location of the core prints. 10. Proper material should always be selected for the pattern after carefully analyzing the factors responsible for their selection. 11. Try to employ full cores always instead of jointed half cores as far as possible. This will reduce cost and ensure greater dimensional accuracy. 12. The use of offset parting, instead of cores as for as possible should be encouraged to the great extent. 13. For large scale production of small castings, the use of gated or match- plate patterns should be preferred wherever the existing facilities permit. 14. If gates, runners and risers are required to be attached with the pattern, they should be properly located and their sudden variation in dimensions should be avoided. 15. Wherever there is a sharp corner, a fillet should be provided, and the corners may be rounded up for easy withdrawal of patterns as well as easy flow of molten metal in the mould.
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PREFACE Manufacturing and workshop
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1 CHAPTER INTRODUCTION 1.1 INTRODUC
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Introduction 3 material into finish
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1.7.3 Metal Forming Processes Intro
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Introduction 7 security procedures
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Introduction 9 FMS and Computer Int
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Introduction 11 towards economic an
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Introduction 13 capabilities of the
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Introduction 15 particular applicat
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2 CHAPTER PLANT AND SHOP LAYOUT 2.1
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Plant and Shop Layout 19 5. Working
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Plant and Shop Layout 21 according
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Plant and Shop Layout 23 5. Better
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Plant and Shop Layout 25 7. Machine
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28 Introduction to Basic Manufactur
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Non-Ferrous Materials 77 impurities
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Non-Ferrous Materials 79 It is made
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Applications Non-Ferrous Materials
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Non-Ferrous Materials 83 5.3.1.8 Gi
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Non-Ferrous Materials 85 springs, h
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5.4.2 Nickel Alloys Non-Ferrous Mat
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5.5 LEAD Non-Ferrous Materials 89 L
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Applications Non-Ferrous Materials
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Non-Ferrous Materials 93 (iv) (v) C
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Non-Ferrous Materials 95 produced i
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Non-Ferrous Materials 97 polymers,
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Non-Ferrous Materials 99 vessel mat
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Binocular Body Non-Ferrous Material
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Melting Furnaces 103 2. Steel (a) E
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Melting Furnaces 105 Blower Stove B
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1. Well Melting Furnaces 107 The sp
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Melting Furnaces 109 operations. In
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Melting Furnaces 111 The chemical c
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Melting Furnaces 113 Firing Door Fi
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Melting Furnaces 115 20 What is ref
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4. Specific Gravity Porperties and
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Porperties and Testing of Metals 11
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12. Creep Porperties and Testing of
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7.5 QUESTIONS Porperties and Testin
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Heat Treatment 131 (b) Movable type
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Heat Treatment 133 steels, in iron
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8.6.1.2 Ferrite Heat Treatment 135
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Heat Treatment 137 1. Normalizing 2
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Annealing is of two types (a) (b) P
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Heat Treatment 141 Sudden cooling o
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Page 148 and 149: Advantages of Aus-Tempering Heat Tr
Page 150 and 151: Heat Treatment 147 carbon steel is
Page 152 and 153: Heat Treatment 149 In the induction
Page 154 and 155: Heat Treatment 151 6. Write short n
Page 156 and 157: Carpentry 153 heartwood, sapwood, p
Page 158 and 159: Carpentry 155 The proper time of cu
Page 160 and 161: Carpentry 157 9.5 DEFECTS IN TIMBER
Page 162 and 163: 9.8 FACTORS INFLUENCING TIMBER SELE
Page 164 and 165: Albumen glue Carpentry 161 It is pr
Page 166 and 167: Carpentry 163 The steel blade and m
Page 168 and 169: Carpentry 165 Jaw Clamp Trigger for
Page 170 and 171: Crosscut Saw Carpentry 167 Cross cu
Page 172 and 173: Jointer Plane Carpentry 169 When a
Page 174 and 175: Carpentry 171 pattern making and wh
Page 176 and 177: Forstner bits These are used for bo
Page 178 and 179: Pincer Carpentry 175 Pincers are co
Page 180 and 181: Carpentry 177 2. Circular Saw A cir
Page 182 and 183: 10 CHAPTER PATTERN AND CORE MAKING
Page 184 and 185: Pattern and Core Making 181 quality
Page 186 and 187: Pattern and Core Making 183 Disadva
Page 188 and 189: 3. Cope and drag pattern Pattern an
Page 190 and 191: Pattern and Core Making 187 11. Seg
Page 192 and 193: Pattern and Core Making 189 density
Page 194 and 195: Pattern and Core Making 191 Core bo
Page 198 and 199: Pattern and Core Making 195 16. Pro
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Page 202 and 203: Strike off bar Foundry Tools and Eq
Page 204 and 205: Foundry Tools and Equipments 201 Fi
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Page 208 and 209: 11.4.2 Classification of Moulding M
Page 210 and 211: Foundry Tools and Equipments 207 5.
Page 212 and 213: 12.3 CONSTITUENTS OF MOLDING SAND M
Page 214 and 215: Mold and Core Making 211 some speci
Page 216 and 217: 12.4.7 Parting sand Mold and Core M
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Page 220 and 221: 12.6. 5 Strength Test Mold and Core
Page 222 and 223: Mold and Core Making 219 Balanced t
Page 224 and 225: Mold and Core Making 221 mixture we
Page 226 and 227: Mold and Core Making 223 Molding sa
Page 228 and 229: 5. Runner Mold and Core Making 225
Page 230 and 231: 12.12 ROLE OF RISER IN SAND CASTING
Page 232 and 233: 12.15 CORE SAND Mold and Core Makin
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Page 236 and 237: 12.20.1 Bench Molding Mold and Core
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Page 244 and 245: 13 CHAPTER CASTING 13.1 INTRODUNCTI
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Casting 243 gravity only and no ext
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Casting 245 (iv) (v) Opening the di
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Casting 247 Applications 1. Carbure
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Casting 249 containing a mixture of
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Semi-Centrifugal Casting Casting 25
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Casting 253 Table 13.1: Probable Ca
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16. Swells 1. Too soft ramming of m
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13.12 QUESTIONS Casting 257 1. Desc
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51. Explain the causes and remedies
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Advantages of forging Some common a
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Forging 263 on it. Forgeable metals
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14.4.6 Open fire and stock fire fur
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Forging 267 10. The place of the me
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Forging 269 pickling in acid, shot
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Hand hammers Forging 271 There are
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Shovel Forging 273 Shovel generally
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Forging 275 opposite to drawing and
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Forging 277 Spring hammers may be m
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14.12 REMOVAL OF DEFECTS IN FORGING
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Forging 281 7. Pneumatic riveting m
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Hot Working of Metals 283 between a
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Hot Working of Metals 285 4. Porosi
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Hot Working of Metals 287 type of t
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Hot Working of Metals 289 Hot pirci
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Hot Working of Metals 291 the punch
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16 CHAPTER COLD WORKING 16.1 INTROD
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16.5 ADVANTAGES OF COLD WORKING Col
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Cold Working 297 Cold working proce
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Cold Working 299 steels are used in
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Cold Working 301 seaming and spinni
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Cold Working 303 Each section must
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Cold Working 305 12. What is impact
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Welding 307 Toe Fusion zone Weld fa
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Welding 309 2. Horizontal position
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Welding 311 5. Gas Metal Arc Weldin
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Welding 313 2. Carburizing welding
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Welding 315 could occur if the cyli
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Welding 317 8. For repairs, calibra
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Welding 319 mains electricity suppl
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Welding 321 6. Chipping hammer Chip
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Welding 323 2. Shielded metal arc w
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Electric power source Welding 325 B
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Welding 327 13. Welders and workers
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Welding 329 Where H = heat generate
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17.7.1.2 Resistance Seam Welding We
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Welding 333 5. Surface of the jobs
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17.8.3 Explosive Welding Welding 33
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Welding 337 be scattered. This scat
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Welding 339 Porosity Fig. 17.31(iii
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Welding 341 (b) (c) Bad welding tec
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Welding 343 exceeding 450°C and be
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Welding 345 7. What effect does wel
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Welding 347 (i) Spot welding (ii) S
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1. Black Iron Sheet Sheet Metal Wor
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Sheet Metal Work 351 (g) Bossing ma
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Sheet Metal Work 353 10. Blow horn
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Sheet Metal Work 355 4. Trammel. Fi
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Sheet Metal Work 357 18.4 FOLDING T
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Sheet Metal Work 359 4. Hem (single
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Sheet Metal Work 361 moveable. When
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Sheet Metal Work 363 4. Blanking. I
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Fitting 365 scriber, semi-circular
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9. Miscellaneous Tools Fitting 367
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19.2.1.11 Surface Gauge or Scribing
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Fitting 371 machined true to keep t
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Fitting 373 the thimble the spindle
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19.2.3.3 Caliper Fitting 375 Calipe
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0 .44 1.5 Fitting 377 12mm 0 5 1015
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Fitting 379 Scriber Spirit-level Sq
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Fitting 381 4. Ring gauge 5. Snap g
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19.2.4.1.3 Universal swivel base ma
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Fitting 385 (A) Type of Cut The mos
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Fitting 387 1. Hand file 2. Flat fi
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Fitting 389 Hand drill Pneumatic dr
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S h a n k D ia Fitting 391 in Fig.
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19.2.7.1 Pliers Fitting 393 Pliers
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Fitting 395 graded from fine to coa
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20 CHAPTER METAL CUTTING 20.1 INTRO
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Metal Cutting 399 turning, facing a
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(vii) Nose radius Metal Cutting 401
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Metal Cutting 403 Continuous chip D
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Metal Cutting 405 20.7 QUESTIONS 1.
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Lathe Machine 407 2. Centre or engi
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Lathe Machine 409 1. Bed 2. Head st
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Lathe Machine 411 1. End of bed gea
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Lathe Machine 413 It is rotated by
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Lathe Machine 415 (b) Operations wh
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Lathe Machine 417 Job Feed lever To
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Lathe Machine 419 longitudinal and
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Lathe Machine 421 22.12 QUESTIONS 1
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Drilling Machine 423 5. Feed handle
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Drilling Machine 425 feeding the dr
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Number sizes Drilling Machine 427 I
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Drilling Machine 429 the main cutti
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Drilling Machine 431 22.5.4 Counter
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22.7 CUTTING SPEED Drilling Machine
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Shaper, Planer and Slotter 435 take
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Shaper, Planer and Slotter 437 the
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Shaper, Planer and Slotter 439 work
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23.8 SHAPER OPERATIONS Shaper, Plan
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Shaper, Planer and Slotter 443 a st
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Shaper, Planer and Slotter 445 Ram
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24 CHAPTER MILLING 24.1 INTRODUCTIO
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24.4 TYPES OF MILLING CUTTERS Milli
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Milling 451 2. Planer milling machi
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Front brace Milling 453 It is an ex
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Face milling Milling 455 Fig. 24.9(
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Milling 457 A B Straddle milling (m
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25.2.1 Production of Metal Powders
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Particle shape Powder Metallurgy 46
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Powder Metallurgy 463 3. The dimens
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25.6 QUESTIONS Powder Metallurgy 46
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Inspection and Quality Control 467
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26.3.7 Fundamental Deviation Inspec
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INDEX A A feeler gauge 381 Abrasive
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Index 477 Cartridge brass 81 Case h
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Index 479 Core sand preparation 230
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Index 481 First aid 30, 39, 41, 49,
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Index 483 High speed steels 62, 66,
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Index 485 Mechanical properties 116
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Index 487 Pattern construction 195
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Index 489 Role of riser 227 Roll fo
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Index 491 Surface cleaning process
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Index 493 W Water seasoning 156 Wax
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