SAND MOLDING MACHINES

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MANUFACTURING TECHNOLOGY GATE MATERIAL

MANUFACTURING TECHNOLOGY GATE MATERIAL

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Cochran boiler

Cochran boiler:-

Cochran boiler consists of a cylindrical shell with a dome shaped top where the space provided for steam. Its crown has a hemispherical shape and thus provides maximum volume of space. Its furnace is seamless; below it there is a grate and ash pit. It has a combustion chamber and smoke box, which are connected through fire tubes. Smoke box is connected to chimney. Various mountings are also fitted on it like

(i) Water level indicator
(ii) Safety valve
(iii) Steam stops valve
(IV) Blow-off cock
(v) Pressure gauge.

Working: The fuel is burnt on the grate inside the furnace. The gases of combustion produced by burning of fuel enter the combustion chamber through the flue tube and strike against the fire brick lining which directs them to pass through number of horizontal tubes, being surrounded by water. After which the gases escape to the atmosphere through smoke box and chimney.

The water surrounded over the fix types get heated and converted into steam. This steams being collected into the crown of boiler. This steam is supplied by steam stop valve.

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Electron Beam Machining (EBM)

Electron Beam Machining (EBM):-

It uses a focused beam of high-velocity electrons to remove material. In this process, a stream of electrons strikes an object and causes rapid melting and vaporization of the material. For drilling applications, a backing material is used on the rear side of the workpiece. When the beam penetrates through the workpiece and contacts the backing material, the high vapor pressure produced by the vaporized backing material expels the molten workpiece material, leaving a hole in the workpiece. The EBM process can be used to machine a variety of materials, and material properties such as hardness, ductility, electrical conductivity, thermal conductivity, and melting points are usually not limiting factors. The greatest industrial use of EBM is the precision drilling of small holes (0.1 to 1.0 mm, or 0.004 to 0.04 in.) in metals. Although some work has been done to apply the EBM process to nonmetallic and curvilinear cutting applications, this industrial application is very limited. Therefore, unless otherwise noted, the descriptions in this article apply only to metallic hole-drilling applications.

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Underwater welding

UNDERWATER WELDING-

Many of us won't have heard of underwater welding, but it's actually a very important thing in many industries. Underwater welding includes a lot of different processes that join steel on offshore oil platforms, pipelines, ships, and in many other applications.
It can be done at regular or at high pressures, and can be done in a wet environment or a dry one. Let's take a look at some of the benefits and downsides of different kinds of welding underwater, and the uses of this interesting technique.
Dry welding is the most useful method for making any weld in very deep water, or in cases where the weld needs to be extremely strong. On many sea structures and vessels, strength is extremely important.The problem is that most conventional dry welding techniques are very expensive, and takes a very long time. While some other techniques, using a smaller hyperbaric chamber for just the area of the weld, are being developed, they're not the standard yet. As they become more popular, wet welding may fall out of use entirely.That's because wet welding, while much cheaper and faster, just isn't all that strong. It tends to create pockets of oxygen and hydrogen gas, as well. These occur due to the electrolysis of water, and can be dangerous and even potentially explosive!
In addition, the majority of wet underwater welds won't last long. They're a temporary fix that needs replacement after only a little while. These welds are best used when time and money are short, and function needs to be maintained - they'll need to be redone again later using a dry process.It's important to remember that there are some limitations on how deep you can weld, as well. Dry welding can be done as deep as eighty meters below the surface of the water, but it requires special diving equipment. Wet welding is much less effective under high pressure, since the join isn't really strong enough to stand up to the forces additional depth will put on it.

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Plasma cutting

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Plasma cutting:

Plasma cutting is a process that is used to cut steel and other metals of different thicknesses (or sometimes other materials) using a plasma torch . In this process, an inert gas (in some units, compressed air) is blown at high speed out of a nozzle; at the same time an electrical arc is formed through that gas from the nozzle to the surface being cut, turning some of that gas to plasma. The plasma is sufficiently hot to melt the metal being cut and moves sufficiently fast to blow molten metal away from the cut.

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Casting Process

Casting:-

Casting is a manufacturing process by which a liquid material is usually poured into a mold, which contains a hollow cavity of the desired shape, and then allowed to solidify. The solidified part is also known as a casting, which is ejected or broken out of the mold to complete the process.Casting is most often used for making complex shapes that would be otherwise difficult or uneconomical to make by other methods.

Advantages:-

1.Size of cast objects vary over large range. An object from 5gm to 200 tonn, anything can be cast.

2.Casting can be effectively used for complex shaped objects.

3.Component made with casting process is lighter than the component made with other machining processes.

4.Casting provides versatility. Wide range of properties can be attained by adjusting percentage of alloying elements.

5.Casting can be made with hair like precision provided proper molding and casting technique is employed.

Disadvantages:-

1.Though casting is cheapest for MASS Production, it becomes non economical in case of JOB production.

2.Sand casting leaves rough surface which needs machining in most of cases. It adds up the cost in production.

3.Again in sand casting, poor dimensional accuracy is achieved.

4.Cast products are superior for compressive loads but they are very poor in tensile or shock loads.(They are brittle).

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EXTRUSION

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Forging tools & Equipment

FORGING and its Types....
Forging is a process in which material is shaped by the application of localized compressive forces exerted manually or with power hammers, presses or special forging machines. The process may be carried out on materials in either hot or cold state. When forging is done cold, processes are given special names. Therefore, the term forging usually implies hot forging carried out at temperatures which are above the recrystallization temperature of the material.

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Forging tools & Equipment

Furnace or hearth: 

A black smith uses a furnace for heating the metal pieces. Furnace consists of four legs, a cast iron or steel body, iron bottom, a chimney and a blower. The main parts of forging furnace are as:

a. HEARTH: 

The iron bottom where fire is lightened is known as hearth. It is provided with fire brick lining.

b. TUYERE: 

A pipe containing from the bottom or rear of the hearth is known as tuyere. It is used to supply the air at high pressure.

c. HOOD: 

The upper part of furnace is called hood. It is made up of mild steel sheet with the fire brick inside it.

d. CHIMNEY: 

Chimney is fitted on the upper end of the hood. It is used for the purpose of easy escaping of exhaust gases and smoke.

e. WATER TANK: 

A small iron tank is attached with the hearth of the furnace. It is used for dipping purposes.

EQUIPMENT USED IN FORGING

Shovel: 

It is used to place the coal into the furnace hearth.

Blower: 

It is used to supply air at high pressure to the hearth.

Poker: 

It is a bent rod used to strike the fire. Poker is made up of mild steel.

Regulator: 

It is used to control the air supply of air to the hearth. Air supply is controlled by increasing or decreasing the passage of air.

Anvil: 

A block on which forging work is done is known as anvil. It is made up of cast iron, steel or wrought iron. It acts as a supporting device for all forging operations since it is capable of withstanding very heavy blows. The anvil is supported either on a iron base, or wooden block or mounted on the foundation. Weight of the anvil varies from 100-150Kg. It is available in many sizes and shapes. 

Common type of anvil used in forging shop has the following parts:
a. Body
b. Horn
c. Chipping block
d. Face
e. Hardie hole
f. Round hole
g. Tail
h. Stand

The centre part is known as body. The projected end is called horn. It is used for making circular jobs. A steel plate riveted on the body is called face. Most of the work is done on face. Chipping block is used for cutting purposes. Holes are used for chisels or punches. At the bottom four legs are attached.

Hammer: 

Hammers are used as striking tools. These are classified as:
a. Hand hammer.
b. Sledge hammer
c. Power hammer

Hand hammer is light in weight used by the smith himself. 
Sledge hammer is heavier in weight and is used by the smith’s helper. All the hammers are divided into four parts namely pean, eye, cheeks and face. Hand hammers are of four types based on shape of the pean. If the pean is along the axis of the handle then it is straight pean hammer when the pean is across the axis of handle then it is called cross pean hammer. In case shape of the pean is same as shape of the face then it is double ended. If the shape of the pean is spherical then it is ball pean hammer. The weight of hand hammer varies from 1-2Kg and that of sledge hammer is 3-8Kg. 

When the quantity of jobs to be produced is more, power hammers are used. Commonly used hammers are spring hammers, pneumatic hammers, steam hammers and drop hammers. 
Power hammers are generally driven by electrical power. The job to be produced is placed on the anvil of the hammer. with the help of lever the weight is allowed to fall on the job. The factors which influence the working of the hammer are:
• Size and shape of the job
• Falling weight of the hammer
• Height of falling weight

Tongs: 

Tongs are used for holding and turning hot metal pieces. Depending upon their use, tongs are classified into many types. All types of tongs have similar construction except the mouth. A tong has two legs riveted from a suitable place. These are made up of mild steel. It is made in two pieces and both the pieces are joined by hinges. The length of the tongs varies from 12” to 18”. It is classified based on the shape of the mouth of the tongs.

Chisels: 

Chisels are used for cutting metal pieces in hot and cold state. Chisels are divided into following categories:
a. Hot chisel
b. Cold chisel
c. Hardie set
Hot chisel is used to cut the metal in hot state and cold chisel to cut the material in cold state. Main difference between these chisels is the cutting angle. In hot chisel cutting angle is 30 degree and in case of cold chisel 60 degree. A hardie set consists of three parts:
a. Shank
b. Body
c. Cutting edge

The shank is fitted into the hardie hole in the anvil. Chisels and the hardie set are made from carbon sheets. It is hardened upto the desired level with proper tempering.

Punches and drifts: 

Punches are made up of high carbon steel and are used for making rough holes in hot metal pieces. Punches are available in different sizes but have a common shape. A drift is a large sized punch used to enlarge a hole.

Flatters: 

As indicated by name, flatters are used to flatten the work piece. It has a plane face joined with a straight shank. It is held in a wire. The material of the flatter is high carbon steel. The body of a flatter is square in cross section.

Fullers: 

Fullers are used for grooving and drawing. These are made in two pieces (lower and upper). Lower part is mounted on the anvil and the upper is held in hand from a wire handle. These are made from high carbon steel and medium carbon steel. These are for hot work only.

Swages: 

Swages are used for giving various shapes to the work pieces. These are made up of high carbon steel and are used in two pieces as in case of fullers.

Swage block: 

It is a cast iron or cast steel rectangular block having a number of holes in it. Holes are made in different sizes and shapes. Its outer sides are also made in sectional forms to receive various types of jobs. It is always plane on a cast iron frame.

Set hammers: 

Set hammers have similar shapes as that of flatters. These are used for making the surface plane, forming and making corners. It is made of tool steel. The job is supported on the anvil and set hammer is hammered on it.

Clamping vice: 

Leg vice is only clamping device used in smithy shop. It is mounted with the table or wooden base. It consists of two jaws, a spring and a leg. Hot work pieces are clamped in it while working.

Bick iron: 

It is also made of tool steel and it is hardened. It’s one portion is similar to the horn of the anvil and a tapered tail on the other side. Due to a taper shank it is fitted in the anvil. 

PRECAUTIONS WHILE USING FORGING TOOLS AND EQUIPMENT

The following points must be kept in mind while working with the forging tools:
1. Hearth should be lightened is proper way.
2. Hammering should not be done in lazy mood.
3. Heavy blows should not be given on the tail of the anvil.
4. Hammers should have proper handle length.
5. Length of the tong should be kept between 15” to 18”. The tong should be kept cool while working with it.
6. Blunt chisels should not be used in the forging shop.
7. Mushroom should not remain on the face of the flatter, punch or chisel.
8. Never use fullers and swages for cold metal.
9. While working on furnace, keep the fire small but deep.
10. Do not let the fire burn hollow.
11. Keep the fire clear from clinkers, particularly while welding.
12. Do not add fresh coke on the top of the fire, put it at the side and pull in later when required.

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