Oxy fuel gas welding
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The document discusses oxy-fuel gas welding (OFW), specifically oxy-acetylene gas welding. It describes OFW as a group of welding processes that produces coalescence by heating materials with an oxy fuel gas flame. Four distinct OFW processes are listed: oxy-acetylene welding, oxy-hydrogen welding, air-acetylene welding, and pressure gas welding. The document then focuses on oxy-acetylene gas welding, explaining how oxygen and acetylene gases are produced and stored in cylinders, as well as the equipment used, including cylinders, regulators, hoses, welding torch, and safety devices.
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Milling machine
Milling is a machining process where a rotary cutter removes material from a workpiece via multiple cutting edges. Milling machines have various specifications including table size, spindle speeds, taper, and weight. Advantages are faster material removal and ability to mount multiple cutters, while disadvantages include high cost and investment in cutters. Common milling machines include horizontal, vertical, universal, and special types based on the column, table, or planer design. Workholding and cutterholding devices are used along with indexing heads for dividing and gear cutting operations.
Shaper machine
The document discusses the shaper machine, which is a reciprocating machine tool used to produce flat surfaces. It has a ram, tool head, and table. The tool head cuts on the forward stroke and returns idle on the back stroke. Flat surfaces can be made horizontally, vertically, or at angles based on the movement of the tool head and table. Shapers are classified based on ram travel direction and cutting stroke action. Other machine tools discussed include the planer, slotter, drilling machines, and broaching machines.
Lathe machine
The document provides information on the history and evolution of lathe machines. It describes early lathe models that were powered manually like the strap lathe, bow lathe, and pole lathe. It then discusses more advanced lathes that used mechanical power sources like the treadle lathe and lathes powered by a great wheel. The document also outlines the main components of a lathe like the headstock, spindle, tailstock, carriage, and tooling. It provides details on workholding devices, lathe operations, and different types of lathes used for various applications.
Stretch forming operations
Stretch forming is a manufacturing process where sheet metal is stretched and bent simultaneously over a die to form large contoured parts. It is performed on a stretch press, where the sheet metal is gripped along the edges by jaws attached to carriages that stretch the sheet against a contoured form die. Special forming processes include hydro forming, where hydraulic fluid acts as a flexible die; rubber pad forming, where sheet metal is pressed between a die and rubber block; and metal spinning, where force is applied to sheet metal wrapped over a rotating mandrel to take its shape.
Bending and drawing
The document discusses bending operations in sheet metal manufacturing. There are two main types of bending: V-bending and edge bending. V-bending is done with a V-shaped die for low production, while edge bending uses a pressure pad and more complex dies for high production. When metal is bent, the inside of the neutral plane is compressed and the outside is stretched. After bending, springback occurs as the bent part partially recovers toward its original shape due to residual elastic energy.
Sheet metal processes - shearing
This document discusses sheet metal processes and operations. Sheet metal is metal formed into thin, flat pieces that can be cut and bent into various shapes. Common materials for sheet metal include steel, aluminum, copper, and other metals. Key sheet metal operations covered include shearing, blanking/punching, bending, drawing, deep drawing, stamping, and others. Factors that influence these operations such as punch and die design, clearance, and lubrication are also addressed.
Extrusion
This document discusses the manufacturing process of extrusion. Extrusion is a compression forming process that forces metal to flow through a die opening to produce a desired cross-sectional shape. There are two main types of extrusion: direct extrusion where the ram forces the billet through the die, and indirect extrusion where the die is mounted to the ram. Extrusion can be performed hot or cold, and defects may occur such as center-bursting or piping due to excessive stresses during the process. Variations on extrusion include impact extrusion for discrete parts and hydrostatic extrusion which uses pressurized liquid to reduce friction.
Rolling
The document discusses various types of rolling mills used to roll metals, including two high, three high, two high reverse, four high, multi, universal, and planetary rolling mills. It describes the basic setup and functions of two high, three high, two high reverse, four high, and cluster rolling mills. Additionally, it mentions tandem, universal, and planetary rolling mills as well as shape rolling operations like ring and thread rolling. Finally, it lists some common defects in rolled metal parts.
Forging
This document discusses various manufacturing technologies related to forging. It describes forging as a metalworking process involving plastic deformation between dies to achieve a desired shape. Forging can be classified based on the process (open die or closed die) or equipment (drop, power hammer/press, hand, or machine forging). The document outlines the key characteristics and applications of these different forging methods. It also describes various forging tools and common forging operations like upsetting, drawing down, setting down, bending, punching, welding, and cutting.
Hot and cold working process, drawing tube, wire and spinning
The document discusses various bulk deformation processes used to shape metals, including hot working, cold working, drawing, and metal spinning. Hot working involves shaping metals above their recrystallization temperature using processes like rolling, forging, and extrusion. Cold working shapes metals below the recrystallization temperature through drawing, bending, and squeezing, increasing strength but decreasing ductility. Drawing is used to produce wires, rods, and tubes by pulling the metal through a die to reduce its size. Metal spinning forms axisymmetric parts by pressing a rotating workpiece against a mandrel using a tool.
Welding defects, soldering and brazing
The document discusses various welding defects that can occur. It divides defects into two categories: external defects, which include incorrect profile, cracks, crater, spatter, and edge melting; and internal defects such as blowholes, cracks, inclusions, and lack of fusion. Specific external defects described include overlap, undercut, excessive penetration, convexity, and concavity. Internal defects result from dissolved gases, inclusions of foreign materials, and incomplete fusion or penetration. The document also covers soldering and brazing processes.
Electron beam and thermit welding
The document discusses two welding processes: electron beam welding and thermit welding. Electron beam welding uses a concentrated beam of electrons to melt and fuse base metals in a vacuum chamber, allowing for high purity welds of dissimilar metals. However, it has high costs and downtime for pumping the vacuum chamber. Thermit welding uses an exothermic reaction between aluminum and a metal oxide to produce enough heat to melt metals for welding without external energy. The reaction separates into a superheated metal and aluminum oxide slag. Thermit welding is used to join shafts, railway tracks, and machinery frames.
Resistance welding
This document discusses various types of resistance welding, including spot welding, seam welding, upset butt welding, and flash butt welding. Spot welding involves overlapping metal sheets and applying a current between electrode tips to generate heat and fuse the metals. Seam welding is similar but uses roller electrodes to continuously weld as the work moves. Upset butt welding joins bars end to end by heating the joint with current and then pressing the parts together. Flash butt welding clamps the parts, applies a current to burn away material, then increases speed and pressure to upset the weld once welding temperature is reached. Resistance welding offers advantages like high production rates and suitability for thin sheets and dissimilar metals.
Plasma arc and friction welding
The document discusses two welding techniques: plasma arc welding and friction welding. Plasma arc welding uses a non-consumable tungsten electrode and very high temperatures, between 8,000 to 25,000°C, to weld materials. It can weld ferrous and non-ferrous metals up to 6mm thick using a DC power source of 70V and currents from 50 to 350 amps. Friction welding involves mechanically inducing sliding motion between two rubbing surfaces below their melting points, but at temperatures high enough to create plastic flow and welding. It is used to weld materials like aluminum and alloys, brass, and steel at rotational speeds of 1,500 to 3,800 rpm and contact pressures of
Electric arc welding processes MIG,SAW,ESW
The document discusses different electric arc welding processes. It describes gas metal arc welding (GMAW or MIG welding) which uses a consumable wire electrode and inert gas shielding. It then explains submerged arc welding which uses a consumable wire electrode and granular flux to shield the arc and weld pool. Finally, it summarizes electroslag welding which melts and joins metals using a pool of molten slag heated by electric current between the metals and a continuously fed filler wire.
Electric arc welding processes metal arc welding, tungsten inter gas
The document discusses various electric arc welding processes. It focuses on metal arc welding and gas tungsten arc welding (GTAW), also known as tungsten inert gas (TIG) welding. Metal arc welding uses an electric arc between an electrode and base metal to weld pieces together. It can be done in various positions and with different materials but is slower than other processes. GTAW uses a tungsten electrode and inert shielding gas to weld reactive metals without contamination. It produces high quality welds but requires more complex equipment than other arc welding methods.
Metal Casting - Manufacturing Technology 1
The document discusses manufacturing technology and focuses on sand casting. It defines key terms like manufacturing, technology, and manufacturing technology. It then discusses the history and process of metal casting. The main focus is on sand casting, including its definition, the 6 step process, and types like green sand and dry sand. Pattern materials and allowances are explained. Finally, it touches on moulding sand constituents, properties, core making, and sand testing methods.
Introduction to joining process, welding classification,terminology,positions
The document discusses various metal joining processes with a focus on welding. It defines welding as the process of joining two metal pieces in a permanent manner using heat, with or without pressure. Various types of welding processes are classified based on whether filler material is used, the type of filler material if used, and whether fusion, plastic deformation, or solid-state joining occurs. Key terms related to welding such as filler metals, fluxes, and welding positions are also defined. The document provides an overview of metal joining processes and fundamentals of welding.
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Oxy fuel gas welding
- 1. MANUFACTURING TECHNOLOGY – I CRAFTED BY: RAMESH KUMAR A Assistant Professor Sona College of Technology Salem 07-02-2019 05:26 1
- 2. OXY – FUEL GAS WELDING (OFW) 07-02-2019 05:26 2
- 3. OXY – FUEL GAS WELDING (OFW) “A group of welding processes which produces coalescence by heating materials with an oxy fuel gas flame or flames with or without the application of pressure and use of filler metal” Four distinct processes Oxy-acetylene welding Oxy-hydrogen welding Air-acetylene welding Pressure gas welding 07-02-2019 05:26 3 Fuel gases Max Temp °C Neutral Temp °C Acetylene 3300 3200 Mythyl acetylene propane 2900 2600 Propylene 2860 2500 Propane 2780 2450 methane 2740 2350 Hydrogen 2870 2390
- 4. OXY – FUEL GAS WELDING (OFW) 07-02-2019 05:26 4
- 5. OXY – ACETYLENE GAS WELDING (OAW) Oxygen gas is produced from commercial liquefaction of air The liquid air is allowed to boil and when nitrogen and argon gas escape, pure liquid oxygen is left The gas is compressed in cylinders at a pressure of 15 Mpa Acetylene gas is produced by the reaction of calcium carbide with water CaC2 + 2H2O = C2H2 + Ca (OH)2 Acetylene gas has the tendency to explode if the pressure is increased So the gas is dissolved in acetone (CH3 – CO – CO3) liquid which acts as a solvent for the gas Usually compressed at 1.7 Mpa The acetylene cylinder will be packed with porous calcium silicate, so the gas is absorbed in an effective way 07-02-2019 05:26 5
- 6. OXY – ACETYLENE GAS WELDING (OAW) 07-02-2019 05:26 6
- 7. OXY – ACETYLENE GAS WELDING (OAW) 07-02-2019 05:26 7
- 8. GAS WELDING EQUIPMENTS Oxygen cylinder 1550 N/mm^2 Black colour 1.8m^3, 3.5m^3, 7m^3 etc., 07-02-2019 05:26 8
- 9. GAS WELDING EQUIPMENTS… Acetylene cylinder 175 N/mm^2 marron colour 1.6m^3, 2.8m^3, 8.4m^3 etc., 07-02-2019 05:26 9
- 10. GAS WELDING EQUIPMENTS… Pressure Regulator To lower the cylinder pressure to a suitable working operating pressure To maintain a steady flow of gas under varying cylinder pressure 07-02-2019 05:26 10
- 11. GAS WELDING EQUIPMENTS… Pressure Gauge Oxygen cylinder (OC) pressure gauge – pressure inside the oxygen cylinder Oxygen line (OL) pressure gauge – outgoing oxygen pressure through the house line Similarly for acetylene AC and AL 07-02-2019 05:26 11
- 12. GAS WELDING EQUIPMENTS… Hoses Reinforce flexible rubber hose Oxygen – green Acetylene - red 07-02-2019 05:26 12
- 13. GAS WELDING EQUIPMENTS… Welding torch Mixing chamber in which oxygen and acetylene will be mixed and the mixture is ignited at the torch tip 07-02-2019 05:26 13
- 14. GAS WELDING EQUIPMENTS… Welding tip Nozzle Through this narrow section that the mixed gases leave the tourch Ignited by a spark lighter or a flame lighter 07-02-2019 05:26 14
- 15. GAS WELDING EQUIPMENTS… Other accessories and safety devices 07-02-2019 05:26 15
- 16. CHARACTERISTICS OF FLAMES 07-02-2019 05:26 16