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

More documents

Recommendations

Info

51. Explain the causes and remedies of the following casting defects: (i) Fins (ii) Shot metal (iii) Shifts (iv) Hard spots (v) Run out (vi) Rattails or buckles (vii) Fusion (viii) Swells (ix) Crushes Casting 259 52. What are the various operations generally required to be performed after shake out for cleaning the castings? 53. Explain the various methods used for removal of gates and risers etc. 54. What are the common methods used for cleaning the surface of the casting? 55. Why are the castings heat treated? 56. How do you repair the castings? Explain. 57. What do you understand from destructive and non-destructive testing methods of inspecting castings? 58. What are the various non-destructive testing methods used for inspection of castings? State their advantages and limitations: 59. Write short notes on the following inspection methods: (i) Visual inspection (ii) Pressure test (iii) Penetrate testing (iv) Radiography (v) Magnetic particle testing (vi) Ultrasonic testing.
260 Introduction to Basic Manufacturing Processes and Workshop Technology 14 CHAPTER FORGING 14.1 INTRODUCTION Forging is an oldest shaping process used for the producing small articles for which accuracy in size is not so important. The parts are shaped by heating them in an open fire or hearth by the blacksmith and shaping them through applying compressive forces using hammers. Thus forging is defined as the plastic deformation of metals at elevated temperatures into a predetermined size or shape using compressive forces exerted through some means of hand hammers, small power hammers, die, press or upsetting machine. It consists essentially of changing or altering the shape and section of metal by hammering at a temperature of about 980°C, at which the metal is entirely plastic and can be easily deformed or shaped under pressure. The shop in which the various forging operations are carried out is known as the smithy or smith’s shop. A metal such as steel can be shaped in a cold state but the application of heat lowers the yield point and makes permanent deformation easier. Forging operation can be accomplished by hand or by a machine hammer. Forging processes may be classified into hot forging and cold forgings and each of them possesses their specific characteristics, merits, demerits and applications. Hand forging process is also known as black-smithy work which is commonly employed for production of small articles using hammers on heated jobs. It is a manual controlled process even though some machinery such as power hammers can also be sometimes used. Black-smithy is, therefore, a process by which metal may be heated and shaped to its requirements by the use of blacksmith tools either by hand or power hammer. In smithy small parts are shaped by heating them in an open fire or hearth. Shaping is done under hand control using hand tools. This work is done in a smithy shop. In smith forging or hand forging open face dies are used and the hammering on the heated metal is done by hand to get the desired shape by judgment. Forging by machine involves the use of forging dies and is generally employed for massproduction of accurate articles. In drop forging, closed impression dies are used and there is drastic flow of metal in the dies due to repeated blow or impact which compels the plastic metal to conform to the shape of the dies. The final shape of the product from raw material is achieved in a number of steps. There are some advantages, disadvantages and applications of forging operations which are given as under. 260
Page 2 and 3:
PREFACE Manufacturing and workshop
Page 4 and 5:
1 CHAPTER INTRODUCTION 1.1 INTRODUC
Page 6 and 7:
Introduction 3 material into finish
Page 8 and 9:
1.7.3 Metal Forming Processes Intro
Page 10 and 11:
Introduction 7 security procedures
Page 12 and 13:
Introduction 9 FMS and Computer Int
Page 14 and 15:
Introduction 11 towards economic an
Page 16 and 17:
Introduction 13 capabilities of the
Page 18 and 19:
Introduction 15 particular applicat
Page 20 and 21:
2 CHAPTER PLANT AND SHOP LAYOUT 2.1
Page 22 and 23:
Plant and Shop Layout 19 5. Working
Page 24 and 25:
Plant and Shop Layout 21 according
Page 26 and 27:
Plant and Shop Layout 23 5. Better
Page 28:
Plant and Shop Layout 25 7. Machine
Page 31 and 32:
28 Introduction to Basic Manufactur
Page 33 and 34:
Page 35 and 36:
Page 37 and 38:
Page 39 and 40:
Page 41 and 42:
Page 43 and 44:
Page 45 and 46:
Page 47 and 48:
Page 49 and 50:
Page 51 and 52:
Page 53 and 54:
Page 55 and 56:
Page 57 and 58:
Page 59 and 60:
Page 61 and 62:
Page 63 and 64:
Page 65 and 66:
Page 67 and 68:
Page 69 and 70:
Page 71 and 72:
Page 73 and 74:
Page 75 and 76:
Page 77 and 78:
Page 80 and 81:
Non-Ferrous Materials 77 impurities
Page 82 and 83:
Non-Ferrous Materials 79 It is made
Page 84 and 85:
Applications Non-Ferrous Materials
Page 86 and 87:
Non-Ferrous Materials 83 5.3.1.8 Gi
Page 88 and 89:
Non-Ferrous Materials 85 springs, h
Page 90 and 91:
5.4.2 Nickel Alloys Non-Ferrous Mat
Page 92 and 93:
5.5 LEAD Non-Ferrous Materials 89 L
Page 94 and 95:
Applications Non-Ferrous Materials
Page 96 and 97:
Non-Ferrous Materials 93 (iv) (v) C
Page 98 and 99:
Non-Ferrous Materials 95 produced i
Page 100 and 101:
Non-Ferrous Materials 97 polymers,
Page 102 and 103:
Non-Ferrous Materials 99 vessel mat
Page 104 and 105:
Binocular Body Non-Ferrous Material
Page 106 and 107:
Melting Furnaces 103 2. Steel (a) E
Page 108 and 109:
Melting Furnaces 105 Blower Stove B
Page 110 and 111:
1. Well Melting Furnaces 107 The sp
Page 112 and 113:
Melting Furnaces 109 operations. In
Page 114 and 115:
Melting Furnaces 111 The chemical c
Page 116 and 117:
Melting Furnaces 113 Firing Door Fi
Page 118 and 119:
Melting Furnaces 115 20 What is ref
Page 120 and 121:
4. Specific Gravity Porperties and
Page 122 and 123:
Porperties and Testing of Metals 11
Page 124 and 125:
12. Creep Porperties and Testing of
Page 126 and 127:
Page 128 and 129:
Page 130 and 131:
Page 132 and 133:
7.5 QUESTIONS Porperties and Testin
Page 134 and 135:
Heat Treatment 131 (b) Movable type
Page 136 and 137:
Heat Treatment 133 steels, in iron
Page 138 and 139:
8.6.1.2 Ferrite Heat Treatment 135
Page 140 and 141:
Heat Treatment 137 1. Normalizing 2
Page 142 and 143:
Annealing is of two types (a) (b) P
Page 144 and 145:
Heat Treatment 141 Sudden cooling o
Page 146 and 147:
Heat Treatment 143 of temperature a
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 196 and 197:
5. Back saw 6. Panel saw 7. Miter s
Page 198 and 199:
Pattern and Core Making 195 16. Pro
Page 200 and 201:
11 CHAPTER FOUNDRY TOOLS AND EQUIPM
Page 202 and 203:
Strike off bar Foundry Tools and Eq
Page 204 and 205:
Foundry Tools and Equipments 201 Fi
Page 206 and 207:
Foundry Tools and Equipments 203 re
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
Page 218 and 219: Mold and Core Making 215 increased
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
Page 234 and 235: 12.16.2.2 Core ramming machines Mol
Page 236 and 237: 12.20.1 Bench Molding Mold and Core
Page 238 and 239: Mold and Core Making 235 This hard
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
Page 248 and 249: Casting 245 (iv) (v) Opening the di
Page 250 and 251: Casting 247 Applications 1. Carbure
Page 252 and 253: Casting 249 containing a mixture of
Page 254 and 255: Semi-Centrifugal Casting Casting 25
Page 256 and 257: Casting 253 Table 13.1: Probable Ca
Page 258 and 259: 16. Swells 1. Too soft ramming of m
Page 260 and 261: 13.12 QUESTIONS Casting 257 1. Desc
Page 264 and 265: Advantages of forging Some common a
Page 266 and 267: Forging 263 on it. Forgeable metals
Page 268 and 269: 14.4.6 Open fire and stock fire fur
Page 270 and 271: Forging 267 10. The place of the me
Page 272 and 273: Forging 269 pickling in acid, shot
Page 274 and 275: Hand hammers Forging 271 There are
Page 276 and 277: Shovel Forging 273 Shovel generally
Page 278 and 279: Forging 275 opposite to drawing and
Page 280 and 281: Forging 277 Spring hammers may be m
Page 282 and 283: 14.12 REMOVAL OF DEFECTS IN FORGING
Page 284 and 285: Forging 281 7. Pneumatic riveting m
Page 286 and 287: Hot Working of Metals 283 between a
Page 288 and 289: Hot Working of Metals 285 4. Porosi
Page 290 and 291: Hot Working of Metals 287 type of t
Page 292 and 293: Hot Working of Metals 289 Hot pirci
Page 294 and 295: Hot Working of Metals 291 the punch
Page 296 and 297: 16 CHAPTER COLD WORKING 16.1 INTROD
Page 298 and 299: 16.5 ADVANTAGES OF COLD WORKING Col
Page 300 and 301: Cold Working 297 Cold working proce
Page 302 and 303: Cold Working 299 steels are used in
Page 304 and 305: Cold Working 301 seaming and spinni
Page 306 and 307: Cold Working 303 Each section must
Page 308 and 309: Cold Working 305 12. What is impact
Page 310 and 311: Welding 307 Toe Fusion zone Weld fa
Page 312 and 313:
Welding 309 2. Horizontal position
Page 314 and 315:
Welding 311 5. Gas Metal Arc Weldin
Page 316 and 317:
Welding 313 2. Carburizing welding
Page 318 and 319:
Welding 315 could occur if the cyli
Page 320 and 321:
Welding 317 8. For repairs, calibra
Page 322 and 323:
Welding 319 mains electricity suppl
Page 324 and 325:
Welding 321 6. Chipping hammer Chip
Page 326 and 327:
Welding 323 2. Shielded metal arc w
Page 328 and 329:
Electric power source Welding 325 B
Page 330 and 331:
Welding 327 13. Welders and workers
Page 332 and 333:
Welding 329 Where H = heat generate
Page 334 and 335:
17.7.1.2 Resistance Seam Welding We
Page 336 and 337:
Welding 333 5. Surface of the jobs
Page 338 and 339:
17.8.3 Explosive Welding Welding 33
Page 340 and 341:
Welding 337 be scattered. This scat
Page 342 and 343:
Welding 339 Porosity Fig. 17.31(iii
Page 344 and 345:
Welding 341 (b) (c) Bad welding tec
Page 346 and 347:
Welding 343 exceeding 450°C and be
Page 348 and 349:
Welding 345 7. What effect does wel
Page 350 and 351:
Welding 347 (i) Spot welding (ii) S
Page 352 and 353:
1. Black Iron Sheet Sheet Metal Wor
Page 354 and 355:
Sheet Metal Work 351 (g) Bossing ma
Page 356 and 357:
Sheet Metal Work 353 10. Blow horn
Page 358 and 359:
Sheet Metal Work 355 4. Trammel. Fi
Page 360 and 361:
Sheet Metal Work 357 18.4 FOLDING T
Page 362 and 363:
Sheet Metal Work 359 4. Hem (single
Page 364 and 365:
Sheet Metal Work 361 moveable. When
Page 366 and 367:
Sheet Metal Work 363 4. Blanking. I
Page 368 and 369:
Fitting 365 scriber, semi-circular
Page 370 and 371:
9. Miscellaneous Tools Fitting 367
Page 372 and 373:
19.2.1.11 Surface Gauge or Scribing
Page 374 and 375:
Fitting 371 machined true to keep t
Page 376 and 377:
Fitting 373 the thimble the spindle
Page 378 and 379:
19.2.3.3 Caliper Fitting 375 Calipe
Page 380 and 381:
0 .44 1.5 Fitting 377 12mm 0 5 1015
Page 382 and 383:
Fitting 379 Scriber Spirit-level Sq
Page 384 and 385:
Fitting 381 4. Ring gauge 5. Snap g
Page 386 and 387:
19.2.4.1.3 Universal swivel base ma
Page 388 and 389:
Fitting 385 (A) Type of Cut The mos
Page 390 and 391:
Fitting 387 1. Hand file 2. Flat fi
Page 392 and 393:
Fitting 389 Hand drill Pneumatic dr
Page 394 and 395:
S h a n k D ia Fitting 391 in Fig.
Page 396 and 397:
19.2.7.1 Pliers Fitting 393 Pliers
Page 398 and 399:
Fitting 395 graded from fine to coa
Page 400 and 401:
20 CHAPTER METAL CUTTING 20.1 INTRO
Page 402 and 403:
Metal Cutting 399 turning, facing a
Page 404 and 405:
(vii) Nose radius Metal Cutting 401
Page 406 and 407:
Metal Cutting 403 Continuous chip D
Page 408 and 409:
Metal Cutting 405 20.7 QUESTIONS 1.
Page 410 and 411:
Lathe Machine 407 2. Centre or engi
Page 412 and 413:
Lathe Machine 409 1. Bed 2. Head st
Page 414 and 415:
Lathe Machine 411 1. End of bed gea
Page 416 and 417:
Lathe Machine 413 It is rotated by
Page 418 and 419:
Lathe Machine 415 (b) Operations wh
Page 420 and 421:
Lathe Machine 417 Job Feed lever To
Page 422 and 423:
Lathe Machine 419 longitudinal and
Page 424 and 425:
Lathe Machine 421 22.12 QUESTIONS 1
Page 426 and 427:
Drilling Machine 423 5. Feed handle
Page 428 and 429:
Drilling Machine 425 feeding the dr
Page 430 and 431:
Number sizes Drilling Machine 427 I
Page 432 and 433:
Drilling Machine 429 the main cutti
Page 434 and 435:
Drilling Machine 431 22.5.4 Counter
Page 436 and 437:
22.7 CUTTING SPEED Drilling Machine
Page 438 and 439:
Shaper, Planer and Slotter 435 take
Page 440 and 441:
Shaper, Planer and Slotter 437 the
Page 442 and 443:
Shaper, Planer and Slotter 439 work
Page 444 and 445:
23.8 SHAPER OPERATIONS Shaper, Plan
Page 446 and 447:
Shaper, Planer and Slotter 443 a st
Page 448 and 449:
Shaper, Planer and Slotter 445 Ram
Page 450 and 451:
24 CHAPTER MILLING 24.1 INTRODUCTIO
Page 452 and 453:
24.4 TYPES OF MILLING CUTTERS Milli
Page 454 and 455:
Milling 451 2. Planer milling machi
Page 456 and 457:
Front brace Milling 453 It is an ex
Page 458 and 459:
Face milling Milling 455 Fig. 24.9(
Page 460 and 461:
Milling 457 A B Straddle milling (m
Page 462 and 463:
25.2.1 Production of Metal Powders
Page 464 and 465:
Particle shape Powder Metallurgy 46
Page 466 and 467:
Powder Metallurgy 463 3. The dimens
Page 468 and 469:
25.6 QUESTIONS Powder Metallurgy 46
Page 470 and 471:
Inspection and Quality Control 467
Page 472 and 473:
26.3.7 Fundamental Deviation Inspec
Page 474 and 475:
Page 476 and 477:
Page 478 and 479:
INDEX A A feeler gauge 381 Abrasive
Page 480 and 481:
Index 477 Cartridge brass 81 Case h
Page 482 and 483:
Index 479 Core sand preparation 230
Page 484 and 485:
Index 481 First aid 30, 39, 41, 49,
Page 486 and 487:
Index 483 High speed steels 62, 66,
Page 488 and 489:
Index 485 Mechanical properties 116
Page 490 and 491:
Index 487 Pattern construction 195
Page 492 and 493:
Index 489 Role of riser 227 Roll fo
Page 494 and 495:
Index 491 Surface cleaning process
Page 496:
Index 493 W Water seasoning 156 Wax
show all

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

Create successful ePaper yourself

Delete template?

Save as template?