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

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Index 489 Role of riser 227 Roll forming 300, 304, 305 Rolling over mechanism 206 Roll-over machine 206 Rotary-hearth furnaces 264 Runner 221, 222, 224-226, 233, 236 S S curve 141, 142 Safe working habits 26, 29 Safety by construction 36 Safety by position 36 Safety committee 27, 28 Safety concepts 27 Safety consciousness 27, 28 Safety guards 35, 36, 45 Safety in carpentry shop 177 Safety objectives 50 Safety of cupola 109, 110 Safety organizations 45 Safety precautions 31-33, 38, 40, 42, 43, 49, 50, 280, 281 Safety programme 27, 28 Safety recommendations for arc welding 326 Safety recommendations for gas welding 316 Safety suggestions 28 Safety methods 36 Sand conditioning 220, 221 Sand mold 208, 212, 222, 224, 228, 238, 239, 240 Sand testing 214 Sawing tools 192 Saws 34, 35, 41, 165, 166 Schematic setup of the electron beam welding 336 Scrapers 165, 171, 366, 387, 388 Screw pitch gauge 365, 370, 381 Screw thread micrometer 374 Scribers 355 Scribing block 369 Seam 349, 352-363 Seam joint 358, 359 Seasoning of timber 155, 157, 178 Seasoning of wood 154, 155 Segmental pattern 187 Selecting pattern materials 184 Selection of cupolas 105 Selection of furnace 102 Semi assembly component 20 Semi universal drilling machine 425 Semi-centrifugal casting 250, 251, 258 Semi-circular protector 355, 365, 378 Semiconductors 76, 94 Sensitive drilling machine 423, 424 Shaft basis system 471, 474 Shaper 434-446 Shaper mechanism 439, 440 Shaper operations 441 Shatter index test 215, 219 Shearing machine 360 Sheet metal operations 296, 299, 351, 359 Sheet metal processing 299, 348 Sheet metal tools 349 Sheet metal work 348-352, 354, 358-361, 363 Shell mold casting 235, 248 Shell molding 248, 249 Shell molding method 235 Shop layout 17-19 Shot peening 296, 304, 305 Shovel 265, 273 Shrinkage allowance 183, 187, 196 Significance of transformations lines 135 Silica gel 234 Silica sand 208-216, 228, 229, 234 Silicon bronze 84
490 Introduction to Basic Manufacturing Processes and Workshop Technology Silicon steel 66, 68 Simple outside caliper 375 Simplification 6, 15 Single point cutting tools 398 Single-cut and double-cut files 385 Sintering 458, 461, 462, 465 Size 466-474 Size of a drilling machine 432 Size of milling machine 453 Sizes of screws 175 Skeleton pattern 184, 186, 196 Slicks 200 Slinging machines 205 Slip gauges 365, 379 Slotter 444-446 Slotter and its various parts 444, 445 Slush casting 243, 258 Smoke seasoning 156 Snap gauge 381 Sodium silicate 210, 234 Soft wood 153, 173, 178 Solder fluxes 344 Soldering 310, 311, 321, 341-344, 347 Soldering methods 310, 343 Solders 343, 344 Solid-state welding processes 311, 333 Sorbite structure 144 Source of infra-red and ultra-violet light 326 Sources of accidents 34, 50 Spark-lighter 316 Special casting 242 Special casting methods 242 Special molding methods 235 Special types of milling machines 451, 453 Specification of a shaper 439 Specification of a lathe 413 Specification of press machine 362 Spherodidal cast iron 59 Spheroidization 139 Spot welding 329, 330, 331, 346, 347 Spot welding electrodes 330 Spot welding machines 329 Spring hammer 275-277 Spring steels 69 Sprue pin 198 Sriking tools 392 Stainless steel 53, 66, 69-71, 75 Stake holder 349, 353, 354 Stakes 349, 352, 353 Standard sand specimen 216, 218 Standard shaper 434, 436, 437, 438, 439 Standardisation 6 Stastical quality control 472 Steady or centre rest 413 Steel production 110, 111 Steel quality 74 Steel rule 364, 365, 367, 374 Steels 52, 53, 60, 62-75 Sterilized dressings 49, 50 Stiffness 119, 120, 129 Stock fire 265, 280 Stop buttons 39 Straight edges 367 Strain 116, 119-126 Strength 117-119, 121, 123, 126, 127 Strength test 215, 217, 218 Striking tools 162, 173, 178 Structural steels 69 Structural transformations 141 Structure 130-150 Structure through transformation 141 Submerged arc welding 310, 323, 324, 338, 346 Supporting tools 364, 366
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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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Shaper, Planer and Slotter 437 the
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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 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 494 and 495: Index 491 Surface cleaning process
Page 496: Index 493 W Water seasoning 156 Wax
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