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

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Welding 311 5. Gas Metal Arc Welding 6. Plasma Arc Welding 7. Atomic Hydrogen Welding 8. Electro-slag Welding 9. Stud Arc Welding 10. Electro-gas Welding 3. Resistance Welding 1. Spot Welding 2. Seam Welding 3. Projection Welding 4. Resistance Butt Welding 5. Flash Butt Welding 6. Percussion Welding 7. High Frequency Resistance Welding 8. High Frequency Induction Welding 4. Solid-State Welding Processes 1. Forge Welding 2. Cold Pressure Welding 3. Friction Welding 4. Explosive Welding 5. Diffusion Welding 6. Cold Pressure Welding 7. Thermo-compression Welding 5. Thermit Welding Processes 1. Thermit Welding 2. Pressure Thermit Welding 6. Radiant Energy Welding Processes 1. Laser Welding 2. Electron Beam Welding (B) Allied Processes 1. Metal Joining or Metal Depositing Processes 1. Soldering 2. Brazing 3. Braze Welding 4. Adhesive Bonding
312 Introduction to Basic Manufacturing Processes and Workshop Technology 5. Metal Spraying 6. Surfacing 2. Thermal Cuting Processes 1. Gas Cutting 2. Arc Cutting Some of the important and widely used welding processes are discussed in the rest of this chapter. 17.5 GAS WELDING PROCESSES A fusion welding process which joins metals, using the heat of combustion of an oxygen /air and fuel gas (i.e. acetylene, hydrogen propane or butane) mixture is usually referred as ‘gas welding’. The intense heat (flame) thus produced melts and fuses together the edges of the parts to be welded, generally with the addition of a filler metal. Operation of gas welding is shown in Fig. 17.5. The fuel gas generally employed is acetylene; however gases other than acetylene can also be used though with lower flame temperature. Oxy-acetylene flame is the most versatile and hottest of all the flames produced by the combination of oxygen and other fuel gases. Other gases such as Hydrogen, Propane, Butane, Natural gas etc., may be used for some welding and brazing applications. Welding torch tip Welding rod Inner cone Direction of welding Molten weld metal Base metal Solidified weld m etal Fig. 17.5 Gas welding operation 17.5.1 Oxy-Acetylent Welding In this process, acetylene is mixed with oxygen in correct proportions in the welding torch and ignited. The flame resulting at the tip of the torch is sufficiently hot to melt and join the parent metal. The oxy-acetylene flame reaches a temperature of about 3300°C and thus can melt most of the ferrous and non-ferrous metals in common use. A filler metal rod or welding rod is generally added to the molten metal pool to build up the seam slightly for greater strength. 17.5.1.1 Types of Welding Flames In oxy-acetylene welding, flame is the most important means to control the welding joint and the welding process. The correct type of flame is essential for the production of satisfactory welds. The flame must be of the proper size, shape and condition in order to operate with maximum efficiency. There are three basic types of oxy-acetylene flames. 1. Neutral welding flame (Acetylene and oxygen in equal proportions).
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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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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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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
Page 294 and 295: Hot Working of Metals 291 the punch
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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
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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
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Page 340 and 341: Welding 337 be scattered. This scat
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Page 356 and 357: Sheet Metal Work 353 10. Blow horn
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Page 362 and 363: 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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