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

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Pattern and Core Making 195 16. Proper allowances should be provided, wherever necessary. 17. As for as possible, the pattern should have a good surface finish because the surface finish of the casting depends totally on the surface finish of the pattern and the kind of facing of the mold cavity. 10.13 PATTERN LAYOUT After deciding the molding method and form of pattern, planning for the development of complete pattern is made which may be in two different stages. The first stage is to prepare a layout of the different parts of the pattern. The next stage is to shape them. The layout preparation consists of measuring, marking, and setting out the dimensions on a layout board including needed allowances. The first step in laying out is to study the working drawing carefully and select a suitable board of wood that can accommodate at least two views of the same on full size scale. The next step is to decide a working face of the board and plane an adjacent edge smooth and square with the said face. Select a proper contraction scale for measuring and marking dimensions according to the material of the casting. Further the layout is prepared properly and neatly using different measuring and making tools specifying the locations of core prints and machined surfaces. Finally on completion of the layout, check carefully the dimension and other requirements by incorporating all necessary pattern allowances before starting construction of the pattern. 10.14 PATTERN CONSTRUCTION On preparing the pattern layout, the construction for making it is started by studying the layout and deciding the location of parting surfaces. From the layout, try to visualize the shape of the pattern and determine the number of separate pieces to be made and the process to be employed for making them. Then the main part of pattern body is first constructed using pattern making tools. The direction of wood grains is kept along the length of pattern as far as possible to ensure due strength and accuracy. Further cut and shape the other different parts of pattern providing adequate draft on them. The prepared parts are then checked by placing them over the prepared layout. Further the different parts of the pattern are assembled with the main body in proper position by gluing or by means of dowels as the case may be. Next the relative locations of all the assembled parts on the pattern are adjusted carefully. Then, the completed pattern is checked for accuracy. Next all the rough surfaces of pattern are finished and imparted with a thin coating of shellac varnish. The wax or leather fillets are then fitted wherever necessary. Wooden fillets should also be fitted before sanding and finishing. The pattern surface once again prepared for good surface and give final coat of shellac. Finally different parts or surfaces of pattern are colored with specific colors mixed in shellac or by painting as per coloring specifications. 10.15 QUESTIONS 1. Define pattern? What is the difference between pattern and casting? 2. What is Pattern? How does it differ from the actual product to be made from it.? 3. What important considerations a pattern-maker has to make before planning a pattern? 4. What are the common allowances provided on patterns and why? 5. What are the factors which govern the selection of a proper material for pattern- making?
196 Introduction to Basic Manufacturing Processes and Workshop Technology 6. What are master patterns? How does their size differ from other patterns? Explain. 7. Discuss the utility of unserviceable parts as patterns. 8. What are the allowances provided to the patterns? 9. Discuss the various positive and negative allowances provided to the patterns. 10. Discuss briefly the match plate pattern with the help of suitable sketch. ? 11. Where skeleton patterns are used and what is the advantage? 12. Sketch and describe the use and advantages of a gated pattern? 13. Give common materials used for pattern making? Discuss their merits and demerits? 14. Write short notes on the following: (i) Contraction scale, (ii) Uses of fillets on patterns, and (iii) Pattern with loose pieces (iv) Uses of cores 15. Discus briefly the various types of patterns used in foundry shop? 16. Define the following? (a) Core prints (b) Mould or cavity (c) Core boxes (d) Shrinkage allowance (e) Chaplets (f) Chills 17. Discuss briefly the various functions of a pattern? 18. Write the color coding for patterns and core boxes?
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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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Heat Treatment 143 of temperature a
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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 196 and 197: 5. Back saw 6. Panel saw 7. Miter s
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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 240 and 241: Mold and Core Making 237 Stirrer Pl
Page 242 and 243: Mold and Core Making 239 11. What i
Page 244 and 245: 13 CHAPTER CASTING 13.1 INTRODUNCTI
Page 246 and 247: 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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