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

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Hot Working of Metals 291 the punch forces the blank through the die opening to form a cup or shell. The multiple dies are also used to accomplish the stages in drawing process. Kitchen utensils and components of food processing industries are manufactured by this process. Punch Heated plate Die Die Heated cup Drawn part Drawn part 15.12 HOT SPINNING Fig. 15.5 Hot drawing Hot spinning is a process in which pressure and plastic flow is used to shape material. Spinning may be either hot or cold and is generally carried over a spinning lathe. In both cases, the metal is forced to flow over a rotating shape by pressure of a blunt tool as shown in Fig. 15.6. The amount of pressure of the blunt tool against the disc controls the generated heat, which helps in forming processes. Sheet being spinned Mandrel Compression pad Tail stock centre Head stock Form Block Tool post Pin Spinning tool Fig. 15.6 Hot spinning QUESTIONS 1. What do you understand by mechanical working of metals? 2. Define re-crystalline temperature. 3. Differentiate between hot and cold working. 4. Define hot working of metals. What are its advantages and disadvantages? 5. Describe with sketches the three methods of hot working. 6. Explain briefly the various methods of hot extrusion with neat sketches.
292 Introduction to Basic Manufacturing Processes and Workshop Technology 7. What is hot extrusion? In how many ways it can be performed? 8. Describe briefly with neat sketches all the process of extrusions. 9. Discuss their relative merits and demerits of different kind of extrusion. 10. How welded pipes and tubes are manufactured? 11. Describe the process of hot extrusion of tubes. 12. What is roll piercing? And for what purpose is it used? 13. Write Short notes on: (a) Hot spinning (b) Hot Extrusion (c) Hot forging (d) Hot drawing. 14. Explain hot rolling and various type of rolling mills used in hot rolling. 15. Write short notes on the following: (i) Hot piercing (ii) Hot forging (iii) Forging 16. How and why are directional properties obtained in a forged component? Discuss their advantages, dis-advantages and applications. 17. What are the advantages of hot extrusion over rolling and forging? 18. With the aid of a sketch, briefly describe the process of spinning. Why is it called a flow turning process?
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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
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12.12 ROLE OF RISER IN SAND CASTING
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12.15 CORE SAND Mold and Core Makin
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12.16.2.2 Core ramming machines Mol
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12.20.1 Bench Molding Mold and Core
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Mold and Core Making 235 This hard
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Mold and Core Making 237 Stirrer Pl
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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 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 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
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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 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
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Page 312 and 313: Welding 309 2. Horizontal position
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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
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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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