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

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Index 483 High speed steels 62, 66, 71, 72 High temperature tempring 144 Hindalium 76, 77, 79 Hoisting equipment 29 Holding and supporting 164 Holding the job 411, 414 Holding tools 364, 366, 382 Hole basis system 471, 474 Hook’s law 124 Horizontal milling machine 450 Horizontal welding position 309 Hose pipes 315 Hot chamber die-casting 244 Hot drawing 285, 290, 291, 292 Hot extrusion 285-292 Hot piercing or seamless tubing 286-288 Hot rolling 285, 286, 287, 292 Hot spinning 286, 291, 292 Hot working 283-286, 291 Hot working processes 283-286 Housekeeping 32, 34, 35, 36 Human causes 32 Hydraulic shaper 436, 440 Hypo-eutectoid steel 138, 139, 140 I Important ferrous metals 53 Important lathe operations 414 Important planes 168 Impurities in cast iron 75 Inconel 76, 87, 88 Indexing and dividing heads 454 Indian factory act 45 Induction furnaces 264 Induction hardening 137, 145, 148, 149, 151 Industrial safety 26-29, 35, 45, 50 Injection molding 255, 256 Injection pressure 246 Inspection 466, 472 Inspection gauges 379, 380 Inspection of castings 259 Installation of plant 18 Interchangeability 6, 15, 467, 474 Interference fit 469, 470 Interlock guards 36, 37 Intermittent feed mechanisms 34 Internal micrometer 372 Inventory 8, 9, 10, 12, 13 Iron ores 52, 53, 75, 103 Iron-carbon equilibrium diagrams 133 ISO 9000 473, 474 Izod test 126, 127 J Jack plane 168, 169 Job production 3 Joining processes 4, 5, 15 Jolt-squeezer machine 205 K Key ways cutting 441 Keyway milling 455 Kinds of machines tools 398 Knee 450-453, 457 L Lack of fusion 340 Lack of penetration 340 Ladle 101, 110, 114, 115, 202-206 Lancing 363 Lap weld joint 307 Lathe 406-421 Lathe accessories 411 Lathe attachment 411, 415
484 Introduction to Basic Manufacturing Processes and Workshop Technology Lathe operations 411, 414, 415 Layout arrangements 20 Lead 76, 80, 83, 84, 89, 91, 101 Lead bronze 91 Lead screw 407, 411, 414, 419 Lifters 199 Lifting hook of crane 101 Limestone 103, 104, 108, 111 Limitations of cold working 294 Limitations of powder metallurgy 463 Limits and fits 474 Limits of size 467, 470 Line layout 22 Liquid carburizing 145, 146 Loam molding 212, 232, 233, 239 Loam sand 212, 233 Loose-piece pattern 185 Low temperature tempering 143 Lower deviation 467, 468 M Machinability properties of steel 67 Machine molding 212, 228, 232, 233, 239 Machine reamer 390 Machine shop 25, 397, 402, 405 Machine tools 21 Machines used in sheet matal shop 360 Machining allowance 188 Machining processes 4 Machining splines 441, 442 Magnalium 76-79 Magnetic properties 116, 118 Magnetic steels 68 Mahogany 153, 154, 157, 180, 181 Main alloys for cold forging or hot forging 262 Maintenance activities 21 Malleability 120, 129 Malleable cast iron 53, 54, 57, 58, 75 Mallet 170, 171, 173, 351 Mandrels 411, 412, 413 Manganese brass 82 Manganese bronze 82, 85 Manganese steel 66-68 Manual metal arc welding 321 Manufacturing 1-16 Manufacturing activities 6, 9, 11, 15, 16 Manufacturing equipments 24 Manufacturing facilities 17 Manufacturing information 2, 13, 14 Manufacturing processes 1-9, 15 Manufacturing shops 1, 4 Manufacturing system 2, 10-14, 15 Mar tempering 142, 144, 145 Markeing tools 364 Market form of steel supply 104, 106 Marking and measuring tools 162 Marking gauge 162-164 Mass production 3, 12 Mass production lathes 408 Match plate pattern 182, 184, 185, 196 Material selection procedure 100 Material selection procedure for components 100 Materials for nuclear engineering purposes 98 Materials used in carpentry shop 159 Measuring 364-379, 395 Measuring and layout tools 192 Measuring and marking 359 Measuring devices 364, 365, 370, 379 Measuring instruments 364, 365, 371 Measuring tools 349, 354, 367, 379, 395 Mechanical effects of welding heat 337
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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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Drilling Machine 429 the main cutti
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Drilling Machine 431 22.5.4 Counter
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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 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 482 and 483: Index 479 Core sand preparation 230
Page 484 and 485: Index 481 First aid 30, 39, 41, 49,
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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