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

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Index 487 Pattern construction 195 Pattern draw machines 205, 206, 207 Pattern layout 195 Pattern materials 180, 184 Pearlite 54-56, 59, 66 Permanent jamming of cupola 109 Permanent mold 237, 238 Permanent mold 242-247, 257 Permanent mold casting 242, 243, 245, 247, 257 Permeability 208-213, 215, 218, 229, 232, 237 Permeability meter 218, 219 Permeability test 215, 218 Phenol formaldehyde 96, 97, 101 Phosphor bronze 84, 85, 93 Physical properties of the metals 116 Pig iron 52-56, 60, 75, 102-105, 110, 111 Pigments 161 Pincer 175 Pit furnace 111, 112 Pit molding 232, 233, 239 Pitch 211, 213, 229, 234 Plain carbon 52, 53, 61, 62, 64, 71, 73, 75 Plain carbon structural steel 75 Plain or simple dividing head 454 Planer 442-444, 446 Planer type milling machine 453 Planes 155, 165, 168 Planning for Industrial Safety 28 Planning tools 193 Plant layout 17-19, 25 Plasma arc welding 311, 317, 346, 347 Plaster mold 232, 236, 237, 239 Plaster of paris pattern 183 Plastic deformation 282, 283, 284, 286 Plastics 92, 94-98, 101, 183 Plastics molding processes 255 Pliers 366, 392, 393 Plug gauges 382 Plutonium 99, 101 Plywood and applications 159 Poker 266, 273 Polishing 393-396 Polymerization 94, 98 Portable drilling machine 423, 424, 432 Position layout 19 Pouring basin 224, 233 Pouring practices 113, 114 Powder making processes 459 Powder metal products 464 Powder metallurgical set-up 463 Powder metallurgy 458, 460, 462-465 Powder metallurgy die setup 462 Powder metallurgy process 458, 463-465 Powder metallurgy product 464, 465 Powder particle size 460 Powdered metal parts 462 Power forging 273, 275 Power operated foundry equipments 204 Power source 318-321, 325, 346 Precision instruments 365, 366 Precision marking work 376 Press machines 348, 361 Press operations 362 Pressure die casting 244, 257 Preventive measures 35, 46 Primary shaping processes 4, 15 Principal components of a shaper 434 Principal hot working processes 286 Principal of lathe machine 406 Principal parts of shaper 437 Principle of limit gauge 380 Principle of upset butt welding 332 Principle parts of a slotter 444
488 Introduction to Basic Manufacturing Processes and Workshop Technology Principle parts of double housing planer 442 Probable causes 252, 253, 258 Process engineering 2 Process layout 23, 24, 25 Process planning 2, 3, 11, 12 Product design 10, 11, 12 Product development 11 Product layout 19, 22-25 Production line 22-24 Production management 10, 13 Production of metallic powder 459, 460 Production of patterns and core boxes 193 Production of steel 104 Production of various cast irons 105 Production planning 23, 24, 25 Production process 1, 2, 3, 7, 10 Profile milling 455 Programmable automation 8, 9 Projection welding 311, 329, 331, 347 Properties of bronzes 83 Properties of engineering materials 118, 129 Properties of metals 116, 118 Properties of plastics 95 Properties of stainless steels 70 Protractor 365, 368, 378 Punch 269, 270, 272, 273, 275, 281 Punching 272, 273, 275, 281 Purpose of cold working 293 Pyrometers 113, 115 Q quality control 1, 6, 7, 9, 11, 14, 15, 466, 472, 473 Quality management standards 473 Quick return mechanism 435, 439, 440 R Rabbet plane 169 Radial drilling machine 423-425, 432, 433 Radial sawing 155 Radiant energy welding processes 311, 335 Radiation 110, 113, 114 Ram-driving mechanism 438 Rammers 198 Rapping or Shake Allowance 188 Reading of micro meter 373 Reamer 366, 389, 390, 396 Reamers 34, 41 Reaming 422, 430, 433 Recovery 121, 122 Re-crystalline temperature 291 Recrystallisation 121, 122 Recrystallisation temperature 283, 284 Reducing welding flame 313 Reducing zone of cupola 107 Refining 102, 103, 115 Refractoriness 208, 209, 212, 213, 215, 216, 229, 231, 237, 238 Refractoriness test 216 Removing a drill from drill machine 427 Reportable accident 30 Resistance projection welding 331 Resistance pyrometer 114 Resistance seam welding 331 Resistance welding 311, 328, 329, 331-333, 338, 346 Rests 409, 411, 413 Reverbratory furnace 112 Revolving parts 34 Rip saw 166, 167 Riser 221, 222, 225, 227, 228, 239 Riser system 227 Rivet header 269, 270
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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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22.7 CUTTING SPEED Drilling Machine
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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 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 486 and 487: Index 483 High speed steels 62, 66,
Page 488 and 489: Index 485 Mechanical properties 116
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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