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

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Cold Working 303 Each section must compress more than the previous section 1 2 3 4 Sheet blank Pressure (a) Pressure Punch Sheet Blank Blank holder Draw die (b) M etal in this area will straighten upon further penetration (c) Fig. 16.6 Metal flow in deep drawing Pressure Forming Punch Die Coined part Fig. 16.7 Embossing
304 Introduction to Basic Manufacturing Processes and Workshop Technology 16.12.5 Coining Fig 16.8 shows the coining process used in cold working operations. It is basically a cold working operation, which is performed in dies where the metal blank is confined and its lateral flow is restricted. It is mainly used for production of important articles such as medals, coins, stickers and other similar articles, which possess shallow configurations on their surfaces. The operation involves placing a metal slug in the die and applying heavy pressure by the punch. The metal flows plastically and is squeezed to the shape between punch and the die. The process, on account of the very high pressures required, can be employed only for soft metals with high plasticity. Forming Punch Section embossed Die 16.12.6 Roll Forming Fig. 16.8 Coining It consists of feeding a continuous metal sheet or strip through a series of rolls whereby it is formed into desired shapes. The roll formed sections can be used in as formed condition with their both edges separate from each other. Alternatively, they can be welded to form a closed section such as tubing and pipes. A number of rolls employed in the series depend upon the shape to be formed. The forming arrangement carries guide rolls and straightening devices also. 16.13 SHOT PEENING It is a process of increasing the hardness and fatigue strength on parts surfaces. The process comprises of throwing a blast of metal shot on to the surface of a component requiring shot peening. It is used to set up a superficial state of surface compression stress, causing the interior of the member to assume an opposite tensile stress. Blast may be thrown either by air pressure or with help of a wheel revolving at high speed. This high velocity blast of metal shot provides a sort of compression over the components surface and increases hardness and strength of the surface and also its fatigue resistance. 16.14 QUESTIONS 1. Differentiate between hot working and cold working. 2. Define cold working of metals. What are its advantages and disadvantages? 3. What are the specific advantages, limitations and applications of cold working? 4. Explain the various cold drawing processes. 5. Using neat sketches explain briefly the process of wire-drawing. 6. Describe the process of cold spinning stating its advantages and specific uses. 7. Explain briefly the stretch forming operation. 8. Write short notes on the cold rolling and cold extrusion. 9. What is cold forging and swaging? 10. What for cold heading is used? 11. Explain the process of rotary swaging with the help of a neat sketch.
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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
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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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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
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Page 276 and 277: Shovel Forging 273 Shovel generally
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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
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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
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Page 304 and 305: Cold Working 301 seaming and spinni
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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 320 and 321: Welding 317 8. For repairs, calibra
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Page 330 and 331: Welding 327 13. Welders and workers
Page 332 and 333: Welding 329 Where H = heat generate
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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
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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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