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

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Fitting 395 graded from fine to coarse. This polishing operation may be performed by hand or mechanically using the rotating disks. The motion in polishing of work on polishing wheel should always be straight and the polishing strokes should cover the whole length of the surface being polished. Finer grade emery disc pr polishing wheel should be used for the fine finish work. Polishing is commonly performed on utensils. Grinding wheel Headstock C ylindrical Job Tailstock Dog Drive plate Upper table Lower table Fig. 19.55 Principle of cylindrical grinding 19.3.3 Surface Coating The various manufacturing processes such as casting, forging, machining, hot working, cold working and joining processes etc. produce different surfaces. Therefore for getting desired surface of the part, subsequent surface preservation processes are needed. These preservation processes are called as surface coating of metals. Coatings on surfaces are employed on most metal parts, either for protective or for decorative or for both purposes. The main objectives of coatings involve for the purpose of decoration, surface protection, corrosion resistance and providing of a hard surface. The surface covering with coating must be uniform and free from runs, checks or peelings. Coatings are commonly applied to the finished components to form the final product. For successful coating, clean and smooth surface finishes is required for assuring good adhesion during coating. Cleaning operations are performed both preparatory to finishing operations and after finishing operations. They are primarily used to remove dirt, oil, oxides, scale, and other harmful ingredients that ultimately affect the life of the product. There are various methods of cleaning, drying, and competitive means of applying the coating. However, the various processes involved in preparing work for coating and applying the coatings are closely interrelated. Galvanizing, parkerizing, electroplating and painting are the common surface coating processes employed for protecting the surfaces of the work pieces. 19.4 QUESTIONS 1. How will you classify the tools commonly used in fitting ? 2. Explain briefly the various clamping tools used in fitting shop using neat sketches. 3. Explain in brief with neat sketches the various types of measuring tools used in fitting shop. 4. Explain the construction and working of vernier caliper using neat sketch. How its least count can be determined? What are its uses?
396 Introduction to Basic Manufacturing Processes and Workshop Technology 5. Explain the construction and working of micrometer with neat sketches. How its least count can be determined? 6. Explain in brief the various types of cutting tools used in fitting shop using neat sketches. 7. Explain in brief the various precautions associated with hand hacksaw, files and chisels. 8. Explain in brief the various types of striking tools used in fitting shop using neat sketches. 9. Explain the various types of files used in fitting shop. How are they classified ? 10. Explain the following tools. (i) Drill (ii) Reamer (iii) Taps (iv) Die and die stock 11. Write short notes on the following operations: (i) Marking (ii) Filing (iii) Chipping (iv) Sawing (v) Drilling (vi) Tapping (vii) Grinding (viii) Polishing (ix) Punching 12. What is the main difference between the hand hammers used in a smithy shop and a fitting shop? 13. What is the difference between hand hacksaw used in fitting shop and the saws used in carpentry shop? 14. Write short notes on the following: (i) Polishing (ii) Buffing (iii) Boring (iv) Milling (v) Broaching (vi) Shaping (vii) Grinding. 15. How will you achieve the following? (i) Rate of production (ii) Accuracy and (iii) Surface finish
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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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Advantages of forging Some common a
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Forging 263 on it. Forgeable metals
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14.4.6 Open fire and stock fire fur
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Forging 267 10. The place of the me
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Forging 269 pickling in acid, shot
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Hand hammers Forging 271 There are
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Shovel Forging 273 Shovel generally
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Forging 275 opposite to drawing and
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Forging 277 Spring hammers may be m
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14.12 REMOVAL OF DEFECTS IN FORGING
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Forging 281 7. Pneumatic riveting m
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Hot Working of Metals 283 between a
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Hot Working of Metals 285 4. Porosi
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Hot Working of Metals 287 type of t
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Hot Working of Metals 289 Hot pirci
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Hot Working of Metals 291 the punch
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16 CHAPTER COLD WORKING 16.1 INTROD
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16.5 ADVANTAGES OF COLD WORKING Col
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Cold Working 297 Cold working proce
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Cold Working 299 steels are used in
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Cold Working 301 seaming and spinni
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Cold Working 303 Each section must
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Cold Working 305 12. What is impact
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Welding 307 Toe Fusion zone Weld fa
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Welding 309 2. Horizontal position
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Welding 311 5. Gas Metal Arc Weldin
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Welding 313 2. Carburizing welding
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Welding 315 could occur if the cyli
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Welding 317 8. For repairs, calibra
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Welding 319 mains electricity suppl
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Welding 321 6. Chipping hammer Chip
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Welding 323 2. Shielded metal arc w
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Electric power source Welding 325 B
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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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Page 368 and 369: Fitting 365 scriber, semi-circular
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Page 396 and 397: 19.2.7.1 Pliers Fitting 393 Pliers
Page 400 and 401: 20 CHAPTER METAL CUTTING 20.1 INTRO
Page 402 and 403: Metal Cutting 399 turning, facing a
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Page 408 and 409: Metal Cutting 405 20.7 QUESTIONS 1.
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Page 424 and 425: Lathe Machine 421 22.12 QUESTIONS 1
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Page 432 and 433: Drilling Machine 429 the main cutti
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Page 438 and 439: Shaper, Planer and Slotter 435 take
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Page 444 and 445: 23.8 SHAPER OPERATIONS Shaper, Plan
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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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