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

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Forging 277 Spring hammers may be made available in various capacities having the tup weights from 30 to 250 kg. Those having top weights 50 to 100 kg and speed of blows up to 300 per minute are in generally used in forging shop. These hammers have a common drawback in their springs getting broken very frequently due to severe vibrations during forging of the jobs in the forging shop. 14.10.2.2 Drop Hammers Drop hammers are operated hydraulically and are widely used for shaping parts by drop hammering a heated bar or billet into a die cavity as shown in Fig. 14.20. A drop forging raises a massive weight and allows it to fall under gravity on close dies in which forge component is allowed to be compressed. The die incorporates its shape on to the hot work piece as shown in Fig. 14.21. Drop hammers are commonly used for forging copper alloys and steel. Safety cover C ylinder Valves C ylinder Down Piston Frame Controls Rolls Up Ram Ram Dies Ram Work piece Dies Anvil Anvil Work piece Dies Anvil Base Base Base Steam hammer Open frame steam hammer Board or gravity hammer Fig. 14.20 Drop hammers Compressive force Cavity Heated billet Die Flashing (Seal) Die Loading of billet Closed dies Fig. 14.21 Close die forging Forged part
278 Introduction to Basic Manufacturing Processes and Workshop Technology 14.10.2.3 Design Principles for drop forging Certain principles for drop forgings generally followed are given as under: 1. The sections of the forging should be balanced about the parting line. Where this is impossible, design for the simplest irregular parting line which approaches a balanced condition. 2. Generous inside fillets and external radio should be allowed. Minimum radius should be 2 mm for small parts and 4 mm for large parts. 3. Sufficient draft should be allowed for easy removal of: the part, as follows: 14.11 DEFECTS IN FORGED PARTS Defects commonly found in forged parts that have been subjected to plastic deformation are as follows. (i) Defects resulting from the melting practice such as dirt, slag and blow holes. (ii) Ingot defects such as pikes, cracks scabs, poor surface and segregation. (iii) Defect due to faulty forging design. (iv) Defects of mismatched forging because of improper placement of the metal in the die. (v) Defects due to faulty design drop forging die. (vi) Defects resulting from improper forging such as seams cracks laps. etc. (vii) Defects resulting from improper heating and cooling of the forging part such as burnt metal and decarburized steel. Some well identified common forging defects along with their reason are given as under. 1. Mismatched forging Reasons Due to non alignment of proper die halves. 2. Brunt and overheated metal Reasons This is caused by improper heating the metal at high temperature or for a long time. 3. Fibred flow lines discontinued Reasons This will occur because of very rapid plastic flow of metal. 4. Scale pits Reason These are formed by squeezing of scale into the metal surface during forging. 5. Oversize components Reasons Due to worn out dies, incorrect dies, misalignment of die halves.
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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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Advantages of Aus-Tempering Heat Tr
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Heat Treatment 147 carbon steel is
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Heat Treatment 149 In the induction
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Heat Treatment 151 6. Write short n
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Carpentry 153 heartwood, sapwood, p
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Carpentry 155 The proper time of cu
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Carpentry 157 9.5 DEFECTS IN TIMBER
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9.8 FACTORS INFLUENCING TIMBER SELE
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Albumen glue Carpentry 161 It is pr
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Carpentry 163 The steel blade and m
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Carpentry 165 Jaw Clamp Trigger for
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Crosscut Saw Carpentry 167 Cross cu
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Jointer Plane Carpentry 169 When a
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Carpentry 171 pattern making and wh
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Forstner bits These are used for bo
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Pincer Carpentry 175 Pincers are co
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Carpentry 177 2. Circular Saw A cir
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10 CHAPTER PATTERN AND CORE MAKING
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Pattern and Core Making 181 quality
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Pattern and Core Making 183 Disadva
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3. Cope and drag pattern Pattern an
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Pattern and Core Making 187 11. Seg
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Pattern and Core Making 189 density
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Pattern and Core Making 191 Core bo
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5. Back saw 6. Panel saw 7. Miter s
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Pattern and Core Making 195 16. Pro
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11 CHAPTER FOUNDRY TOOLS AND EQUIPM
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Strike off bar Foundry Tools and Eq
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Foundry Tools and Equipments 201 Fi
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Foundry Tools and Equipments 203 re
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11.4.2 Classification of Moulding M
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Foundry Tools and Equipments 207 5.
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12.3 CONSTITUENTS OF MOLDING SAND M
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Mold and Core Making 211 some speci
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12.4.7 Parting sand Mold and Core M
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Mold and Core Making 215 increased
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12.6. 5 Strength Test Mold and Core
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Mold and Core Making 219 Balanced t
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Mold and Core Making 221 mixture we
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Mold and Core Making 223 Molding sa
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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
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
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Page 258 and 259: 16. Swells 1. Too soft ramming of m
Page 260 and 261: 13.12 QUESTIONS Casting 257 1. Desc
Page 262 and 263: 51. Explain the causes and remedies
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 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
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Page 292 and 293: Hot Working of Metals 289 Hot pirci
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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
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Page 316 and 317: Welding 313 2. Carburizing welding
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Page 320 and 321: Welding 317 8. For repairs, calibra
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Page 326 and 327: Welding 323 2. Shielded metal arc w
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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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