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

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Index 479 Core sand preparation 230 Coreless type induction furnace 112 Core-making 240 Counter-boring 430, 431 Counter-sinking 430, 431 Crank and slotted link mechanism 440 Crank shaper 436 Creep 121, 123, 128, 129 Critical temperatures 136 Cr-Mo-steel 73 Cross rail of shaper 438 Crosscut saw 167 Crucible 103, 111, 112, 114, 197, 202, 203, 204, 206 Cupola furnace 102, 103, 105, 107, 109, 110, 114 Cupola furnace 105, 106, 109 Cutting edge 398, 399, 400, 401, 402 Cutting gears on shaper 442 Cutting speed 420, 421, 433 Cutting tools 162, 165, 178, 349, 353, 364, 366, 384, 387, 396, 397-405 Cyaniding 137, 145, 147, 149, 150, 151 D De Levaud casting process 250 Dead carbon steel 53, 62 Defects due to abnormal growth of trees 157 Defects due to conversion and seasoning 157 Defects due to fungi and insects 158 Defects in forged parts 278 Defects in forging 279, 281 Defects in timber 157, 178 Delta metal 82 Demerits of hot working 285 Depth micrometer 372, 374 Design considerations in pattern making 194 Design principles for drop forging 278 Designation of steel 64, 73, 75 Destructive and non-destructive testing methods 259 Destructive tests 123 Dextrin 210, 211, 229, 231, 234 Dial indicators 377 Diamond 92, 93 Die casting 242, 244, 245, 246, 247, 257 Die casting machine 244, 245, 246, 257 Die-casting dies 245 Dies used for wire drawing 298 Diesel engine piston 101 Difference between shaper and planer 443 Different cutting tools 40 Different hand tools 40 Different kind of hammers 350 Different methods of extrusion 290 Directional solidification 245, 249, 255, 257 Dis-advantages and applications of metallic molding 238 Disadvantages of cold working 295 Distortion allowance 187, 188 Dovetail saw 167 Down-milling 448 Draft or taper allowance 188 Drag 213, 221, 222, 228, 233 Drag pattern 221, 222 Draw spike 199 Drawing out 271, 274 Drawing process 291 Drift 269, 272, 281 Drill 366, 367, 368, 370, 382, 383, 388, 389, 390, 393, 394, 396 Drill body 428 Drill material 429 Drill nomenclature 428 Drill point 427, 428, 430 Drilling 422-433
480 Introduction to Basic Manufacturing Processes and Workshop Technology Drilling of a lathe 420 Drills sizes 427 Drop and press forgings 279 Drop hammers 275, 277 Dry powder extinguishers 48 Dry sand 209, 212, 214, 215, 217, 222, 228, 232, 233, 239, 240 Dry sand cores 232, 240 Dry strength 211, 214, 217, 239 Ductile cast iron 53, 56, 57, 75 Ductility 119, 120, 121, 129 Dump core box 190 Duralumin 76-78 E EBW process 336, 337 Edge of sheet metal component 358 Effect of accidents 31 Effects of forging 267 Effect of hot working on mechanical properties 284 Effect of impurities on steel 61 Effect of riser 228 Effects of welding heat 337 Efficiency of cupola 109 Electric arc welding 318, 345, 346 Electric preventive measures 46 Electric safety devices 46 Electrical properties 116, 117, 129 Electrical safety measures 46 Electrode holder 320, 327, 329 Electron beam welding (EBW) 335 Elements in steel 62, 65 Elements of the gating system 224 Elements of tool signature 399, 400 Embossing 296, 302, 303, 305 Embossing process 302 End milling 449, 455 Endogenous trees 152, 178 Engineering material properties 116 Engineering materials 51, 52, 75 Environmental causes 32 Eutectoid 131, 132, 135, 137-141 Explosive Welding 311, 333, 335 Extrusion molding 255, 256 Extrusion molding process 256 Extrusion setup 289 F Fabricating of plastics 97 Face plates 411, 412 Factors affect the cutting speed 420 Factors controlling gating design 226 Factors influence the selection of a power 319 Factory act regulation 44 Feed 407, 409, 410, 411, 416, 418-421, 423, 424, 425, 430, 432, 433 Feed mechanism 409, 410 Felling 154, 157 Ferrite 131-138, 139, 142, 143 Ferritic stainless steels 70 Ferrous materials 71 Files 366, 374, 383-387, 396 Files and rasps 171 Filler material 321, 341, 342 Filler metal 306, 312, 320, 325, 328, 333, 336, 340, 342, 343 Fillet and radius gauge 365, 370, 381 Finishing operations 394, 395 Finishing processes 4-6 Fire points 47 Fire prevention 28, 47 Fire-extinguisher 47 Firmer chisel 170, 171
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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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Drilling Machine 425 feeding the dr
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Number sizes Drilling Machine 427 I
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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 442 and 443: Shaper, Planer and Slotter 439 work
Page 444 and 445: 23.8 SHAPER OPERATIONS Shaper, Plan
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Page 448 and 449: Shaper, Planer and Slotter 445 Ram
Page 450 and 451: 24 CHAPTER MILLING 24.1 INTRODUCTIO
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Page 454 and 455: Milling 451 2. Planer milling machi
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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 478 and 479: INDEX A A feeler gauge 381 Abrasive
Page 480 and 481: Index 477 Cartridge brass 81 Case h
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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