MANUFACTURING TECHNOLOGY-I PROF. (DR.) K.S. YADAV Professionally U.K. Trained Educationist and Writer Director Satyam College of Engineering and Management, Delhi-NCR Formerly Director Subharti Institute of Technology and Engineering, Meerut, Shri Balwant Institute of Technology, Sonepat, South Point College of Engineering and Management, Sonepat, ABSS Institute of Technology, Meerut, Aravali College of Engineering and Management, and Rawal Institutions, Faridabad Vayu Education of India 2/25, Ansari Road, Darya Ganj, New Delhi-110 002 (An ISO 9001:2008 Certified Company)
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MANUFACTURING
TECHNOLOGY-I
PROF. (DR.) K.S. YADAVProfessionally U.K. Trained Educationist and Writer
Director
Satyam College of Engineering and Management, Delhi-NCR
Formerly Director
Subharti Institute of Technology and Engineering, Meerut,
Shri Balwant Institute of Technology, Sonepat,
South Point College of Engineering and Management, Sonepat,
ABSS Institute of Technology, Meerut,
Aravali College of Engineering and Management, and Rawal Institutions, Faridabad
Vayu Education of India2/25, Ansari Road, Darya Ganj, New Delhi-110 002
1.4 Design Considerations in Pattern Making ............................................................................ 31.5 Pattern Construction ............................................................................................................. 51.6 Pattern Colours / Colouring Codes For Patterns ................................................................... 51.7 Core Prints / Types of Core Prints ........................................................................................ 61.8 Pattern Allowances ................................................................................................................. 71.9 Providing Fillets on Patterns .................................................................................................. 9
1.10 Functions of a Pattern ........................................................................................................... 91.11 Types ................................................................................................................................... 101.12 Moulding Sands and Its Desirable Properties ..................................................................... 121.13 Moulding Sand .................................................................................................................... 121.14 Classfication of Sand ........................................................................................................... 121.15 Types of Moulding Sand ...................................................................................................... 121.16 Properties of Moulding Sand .............................................................................................. 131.17 Mould making ..................................................................................................................... 141.18 Foundry Tools ...................................................................................................................... 151.19 Disadvantages of Casting .................................................................................................... 191.20 Elements of a Gating System ............................................................................................... 211.21 Die Casting ......................................................................................................................... 271.22 Advantages and Disadvantages of Die-Casting .................................................................... 281.23 Hot Chamber Die-casting Machine .................................................................................... 291.24 Cold Chamber Die-casting Machine................................................................................... 301.25 Cupola Furnace ................................................................................................................... 311.26 Charging of Cupola ............................................................................................................. 321.27 Cupola Operation ................................................................................................................ 331.28 Zones in Cupola .................................................................................................................. 341.29 Capacity of Cupola .............................................................................................................. 35
2. FORGING AND WELDING ............................................................................. 40
2.1 Forging ................................................................................................................................ 402.2 Drop Forging ....................................................................................................................... 41
CONTENTS
Manufacturing Technology-Iiv
2.3 Pneumatic Power Hammer .................................................................................................. 412.4 Forging Press ....................................................................................................................... 432.5 Power Press – Mechanical Press ......................................................................................... 432.6 Advantages of forging Process ............................................................................................. 442.7 Disadvantages of Forging Process ....................................................................................... 452.8 Introduction ........................................................................................................................ 472.9 Weldability ........................................................................................................................... 47
2.10 Concept Of Welding (Types Of Welding) ............................................................................ 472.11 Classification Of Welding Processes ................................................................................... 472.12 Forge or Smithy Welding ..................................................................................................... 482.13 RResistance Welding ........................................................................................................... 482.14 FFusion ............................................................................................................................... 522.15 Thermit Welding ................................................................................................................. 522.16 Electric Arc Welding ............................................................................................................ 53
2.16.1 ARC Welding Equipments ....................................................................................... 532.16.2 ARC Column Theory .............................................................................................. 552.16.3 Difference between A.C. and D.C. Arc Welding ...................................................... 55
2.17 Electrodes ............................................................................................................................ 562.17.1 Functions of Flux Coated on Electrodes ................................................................... 572.17.2 Welding Current ..................................................................................................... 572.17.3 Selection of Electrodes ............................................................................................. 572.17.4 Electrode Size ......................................................................................................... 582.17.5 Electrode Coverings ................................................................................................ 582.17.6 Polarity .................................................................................................................. 582.17.7 Precautions During Electric Arc Welding ................................................................. 58
2.19 Welding Defects .................................................................................................................. 632.20 Advantages And Disadvantages Of Welded Joints ............................................................... 632.21 Gas Welding ........................................................................................................................ 66
2.21.1 Working Pressure .................................................................................................... 662.22 A Assembly And Care In Use Of Equipment68
3. POWDER METALLURGY AND HEAT TREATMENT ....................................... 80
3.1 Powder Metallurgy ............................................................................................................... 803.2 The Powder Metallurgy Process .......................................................................................... 803.3 Production of Metal Powders .............................................................................................. 803.4 Main Characteristics of Metal Powders .............................................................................. 82
Contentsv
3.5 Advantages and Disadvantages of Powder Metallurgy ......................................................... 823.6 Disadvantages And Limitations ........................................................................................... 833.7 Heat Treatment .................................................................................................................... 833.8 Purpose of Heat Treatment .................................................................................................. 843.9 Principles of Heat Treatment ............................................................................................... 85
4.1 Lathedfd .............................................................................................................................. 984.1.1 Main Parts of a Lathe ............................................................................................ 984.1.2 Lathe Speicfications ................................................................................................ 984.1.3 Working Principle of a Lathe ................................................................................ 1014.1.4 Types of L athes .................................................................................................... 102
5.1 Definitions ........................................................................................................................ 1105.2 Classification of Measuring Equipment ............................................................................ 1125.3 Technical specifications of measuring instruments ............................................................ 1135.4 Micrometers ...................................................................................................................... 114
5.4.1 Description of a Micrometer ................................................................................. 1155.4.2 Sources of Errors in Micrometers .......................................................................... 1165.4.3 Precautions in using tghe Micrometer .................................................................... 117
5.5 The Comparator................................................................................................................ 1175.6 Uses of comparators .......................................................................................................... 1185.7 Types of comparators ........................................................................................................ 1185.8 Mechancial Compartors .................................................................................................... 1195.9 Gauge ................................................................................................................................ 119
5.9.1 Classification of Gauges ........................................................................................ 1195.9.2 Description of Some Commonly Used Gauges ........................................................ 120