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

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INDEX A A feeler gauge 381 Abrasives 41 Accidents 26-38, 44, 45, 47, 49, 50 Accidents in industries 30 Acid pickling 298 Additions in polymer 98 Additives 208-212, 214, 220, 223, 228, 230, 236, 238 Adhesives 159, 160 Adjustable frame hacksaw 392 Adjustable gap gauge 381 Admiralty brass 81 Admiralty gun metal 90, 91 Advantages of continuous casting 251, 295 Advantages of die casting over sand casting 247 Advantages of forging 261, 267, 268 Advantages of powder metallurgy 462 Advantages of resistance welding 333 Age hardening 151 Air furnace 102, 112, 113 Air seasoning 156 Allotropy of iron 131 Allowance 469, 470, 474 Alloy cast iron 53, 54, 58 Alloy steel 52, 53, 64, 66, 68, 73, 75 Alloying elements in steel 65 Alpha iron 132, 136 Aluminium 76-80, 85, 89, 92, 93, 99, 100, 101 Aluminium alloy 77, 101, 187 Aluminium bronze 85 Annealing 130, 138, 139, 140, 142, 150 Annealing and normalizing 139 Antioch process 237 Anvil 269, 270, 272, 273, 274, 275, 280, 281 Application of heat and solder 344 Applications of continuous casting 252 Applications of cupola 108 Applications of cyaniding 147 Applications of different plain carbon steels 75 Applications of forging 260, 261 Applications of powder metallurgy 464, 465 Applications of rolling 288 Applications of spot welding 330 Arbor 447, 449, 452, 453, 455 Arc welding equipment 318, 327 Arc welding equipment, setup and related tools 318 Arc welding equipments 327 Arc welding machines 325, 327, 328 475
476 Introduction to Basic Manufacturing Processes and Workshop Technology Arc welding processes 310, 317 Atomic hydrogen welding 311, 317, 346 Atomization 459, 465 Auger 165, 172, 173 Aus-tempering 144, 145, 151 Austenite 132-136, 138, 140-143, 147 Austenitic stainless steel 70, 71 Automatic guards 36, 37 Automation 2, 3, 7, 8, 9, 15, 16 Availability of steel in market 72 Axe 165, 172 B Bainite 142, 143, 144, 145 Bakelite 96, 97 Band saw 176, 177, 178 Basic principle of arc welding 317 Batch production 3, 12 Batch furnaces 131 Bauxite 76, 77 Bearing or antifriction alloys 76, 90 Bed of high precision lathe 101 Bell metal 85 Bellows 202 Bench drilling machine 388 Bench lathe 406, 407 Bending 267, 272, 273, 296, 300, 301, 305 Beryllium bronze 84 Bessemer’s matte 86 Bevel gauge 162, 163, 377 Beveled edge firmer chisel 170 Bever protractor 368 Bick iron 352 Binder 208, 209, 210, 213, 220, 221, 223, 228, 229, 230, 231, 234, 236, 238, 240 Black heart malleable iron casting 58 Blanking 296, 299, 300, 348, 359, 363 Blast furnace 102, 103, 104, 114 Blending 458, 461, 465 Blending of metallic powders 461 Boring 406, 415, 422, 430, 431, 433 Boring tool 165, 172, 178, 430, 433 Box or batch type furnaces 264 Brass and bronze pattern 182 Brasses 80, 83, 101 Braze welding 311, 321, 342, 347 Brazing 310, 311, 312, 321, 341, 342, 347 Brittleness 119, 120, 129 Broaching machine 445 Bronzes 80, 83, 84, 101 Built-up edge 402, 404 Bulk modulus 120, 125 Butt weld joint 308 C CAD 8, 9, 12, 13, 15, 16 CAD/CAM 8, 13, 15 Calipers 365, 375 CAM 8, 9, 12, 13, 14, 15, 16 Capstan and turret lathe 408 Carbides 92, 93 Carbon arc welding 310, 317, 321, 346 Carbon tool steel 64, 71, 75 Carbon-dioxide gas molding 234 Carburizing welding flame 313 Carning or C process 248 Carpenter vice 164, 165 Carpentry 152, 153, 154, 159, 162, 163, 164, 165, 167, 171, 173, 174, 176, 177, 178 Carpentry machines 176 Carpentry shop 152, 153, 159, 162, 163, 165, 171, 173, 174, 177, 178 Carpentry tools 178 Carriage 407-411, 413, 418, 419, 421
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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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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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Page 430 and 431: Number sizes Drilling Machine 427 I
Page 432 and 433: Drilling Machine 429 the main cutti
Page 434 and 435: Drilling Machine 431 22.5.4 Counter
Page 436 and 437: 22.7 CUTTING SPEED Drilling Machine
Page 438 and 439: Shaper, Planer and Slotter 435 take
Page 440 and 441: Shaper, Planer and Slotter 437 the
Page 442 and 443: Shaper, Planer and Slotter 439 work
Page 444 and 445: 23.8 SHAPER OPERATIONS Shaper, Plan
Page 446 and 447: Shaper, Planer and Slotter 443 a st
Page 448 and 449: Shaper, Planer and Slotter 445 Ram
Page 450 and 451: 24 CHAPTER MILLING 24.1 INTRODUCTIO
Page 452 and 453: 24.4 TYPES OF MILLING CUTTERS Milli
Page 454 and 455: Milling 451 2. Planer milling machi
Page 456 and 457: Front brace Milling 453 It is an ex
Page 458 and 459: Face milling Milling 455 Fig. 24.9(
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 480 and 481: Index 477 Cartridge brass 81 Case h
Page 482 and 483: Index 479 Core sand preparation 230
Page 484 and 485: Index 481 First aid 30, 39, 41, 49,
Page 486 and 487: Index 483 High speed steels 62, 66,
Page 488 and 489: Index 485 Mechanical properties 116
Page 490 and 491: Index 487 Pattern construction 195
Page 492 and 493: Index 489 Role of riser 227 Roll fo
Page 494 and 495: Index 491 Surface cleaning process
Page 496: Index 493 W Water seasoning 156 Wax
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