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

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Drilling Machine 429 the main cutting edges can enter into the material, the clearance faces slope backwards in a curve. The clearance angle is measured at the face edge, must amount to 5° up to 8°. Point angle is the included angle of the cone formed by the lips. Shank Neck Overall length Body Flute length Helix angle Lead or helix Axis Tang Flute Heel Land Cutting portion Diameter Body clearance dia. Land Chisel edge Point Flank Point angle Depth or body clearance Web or core thickness Outer corner Dia. Lip length Outer corner Lip Face Lip clearance angle Enlarged view of clearance at a Chisel edge corner A Helix angle at periphery X Enlarged sec X - X Fig. 22.5 Geometry and nomenclature of twist drill X Relative lip height Top rake angle Cutting angle Front clearance angle 22.4.2 Drill Material Drills are made are made up of high speed steel. High speed steel is used for about 90 per cent of all twist drills. For metals more difficult to cut, HSS alloys of high cobalt series are used. 22.5 OPERATIONS PERFORMED ON DRILLING MACHINE A drill machine is versatile machine tool. A number of operations can be performed on it. Some of the operations that can be performed on drilling machines are:
430 Introduction to Basic Manufacturing Processes and Workshop Technology 1. Drilling 2. Reaming 3. Boring 4. Counter boring 5. Countersinking 6. Spot facing 7. Tapping 8. Lapping 9. Grinding 10. Trepanning. The operations that are commonly performed on drilling machines are drilling, reaming, lapping, boring, counter-boring, counter-sinking, spot facing, and tapping. These operations are discussed as under. 22.5.1 Drilling This is the operation of making a circular hole by removing a volume of metal from the job by a rotating cutting tool called drill as shown in Fig. 22.6. Drilling removes solid metal from the job to produce a circular hole. Before drilling, the hole is located by drawing two lines at right angle and a center punch is used to make an indentation for the drill point at the center to help the drill in getting started. A suitable drill is held in the drill machine and the drill machine is adjusted to operate at the correct cutting speed. The drill machine is started and the drill starts rotating. Cutting fluid is made to flow liberally and the cut is started. The rotating drill is made to feed into the job. The hole, depending upon its length, may be drilled in one or more steps. After the drilling operation is complete, the drill is removed from the hole and the power is turned off. 22.5.2 Reaming This is the operation of sizing and finishing a hole already made by a drill. Reaming is performed by means of a cutting tool called reamer as shown in Fig. 22.7. Reaming operation serves to make the hole smooth, straight and accurate in diameter. Reaming operation is performed by means of a multitooth tool called reamer. Reamer possesses several cutting edges on outer periphery and may be classified as solid reamer and adjustable reamer. 22.5.3 Boring Fig. 22.8 shows the boring operation where enlarging a hole by means of adjustable cutting tools with only one cutting edge is accomplished. A boring tool is employed for this purpose. Drill feeds and rotates Work stationary Fig. 22.6 Drilling operation Reamer rotates Work stationary Fig. 22.7 Reaming operation Tool fee ds Work rotates Fig. 22.8 Boring operation
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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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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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Page 400 and 401: 20 CHAPTER METAL CUTTING 20.1 INTRO
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Page 436 and 437: 22.7 CUTTING SPEED Drilling Machine
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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Page 450 and 451: 24 CHAPTER MILLING 24.1 INTRODUCTIO
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Page 460 and 461: Milling 457 A B Straddle milling (m
Page 462 and 463: 25.2.1 Production of Metal Powders
Page 464 and 465: Particle shape Powder Metallurgy 46
Page 466 and 467: Powder Metallurgy 463 3. The dimens
Page 468 and 469: 25.6 QUESTIONS Powder Metallurgy 46
Page 470 and 471: Inspection and Quality Control 467
Page 472 and 473: 26.3.7 Fundamental Deviation Inspec
Page 478 and 479: INDEX A A feeler gauge 381 Abrasive
Page 480 and 481: 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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