Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
1. CASTING
1.1 What is 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 materials are usually metals or
various cold setting materials that
together; examples are epoxy, concrete, plaster and clay.Casting is most often
used for making complex shapes that would be otherwise difficult or uneconomical
to make by other methods.
1.2
Sand Casting
characterized by using sand as the mold material. The term "sand casting" can
also refer to an object produced via the sand casting process. Sand castings are
produced in specialized factories called foundries. Over 70% of all metal castings
are produced via a sand casting process.
Sand casting is relatively cheap and sufficiently refractory even for steel foundry
use. In addition to the sand, a suitable bonding agent (usually clay) is mixed or
occurs with the sand. The mixture is moistened, typically with water, but sometimes
with other substances, to develop strength and plasticity of the clay and to make
the aggregate suitable for molding. The sand is typically contained in a system of
frames or mold boxes known as a flask. The mold cavities and gate system are
created by compacting the sand around models, or patterns, or carved directly into
the sand.
1.3
1.5
Methods
In general, we can distinguish between two methods of sand casting; the first one
using green sand and the second being the air set method
process. Green sand is not green in color, but "green" in the sense that it is used in
a wet state (akin to green wood). Unlike the name suggests, "green sand" is not a
type of sand on its own, but is rather a mixture of:
silica sand (SiO2), or chromite sand (FeCr2O), or zircon sand (ZrSiO4), 75 to
85%, or olivine, or staurolite, or graphite.
bentonite (clay), 5 to 11%
water, 2 to 4%
inert sludge 3 to 5%
anthracite (0 to 1%)
There are many recipes for the proportion of clay, but they all strike different
balances between moldability, surface finish, and ability of the hot molten metal to
degas. The coal, typically referred to in foundries as sea-coal, which is present at a
ratio of less than 5%, partially combusts in the presence of the molten metal
leading to offgassing of organic vapors. Green Sand for non-ferrous metals do not
use coal additives since the CO created is not effective to prevent oxidation. Green
Sand for aluminum typically uses olivine sand (a mixture of the minerals forsterite
and fayalite which are made by crushing dunite rock). The choice of sand has a lot
to do with the temperature that the metal is poured. At the temperatures that
copper and iron are poured, the clay gets inactivated by the heat in that the
montmorillonite is converted to illite, which is a non-expanding clay. Most foundries
do not have the very expensive equipment to remove the burned out clay and
substitute new clay, so instead, those that pour iron typically work with silica sand
that is inexpensive compared to the other sands. As the clay is burned out, newly
mixed sand is added and some of the old sand is discarded or recycled into other
uses. Silica is the least desirable of the sands since metamorphic grains of silica
sand have a tendency to explode to form sub-micron sized particles when thermally
shocked during pouring of the molds. These particles enter the air of the work area
and can lead to silicosis in the workers. Iron foundries spend a considerable effort
on aggressive dust collection to capture this fine silica. The sand also has the
dimensional instability associated with the conversion of quartz from alpha quartz
to beta quartz at 1250 degrees F. Often additives such as wood flour are added to
create a space for the grains to expand without deforming the mold. Olivine,
Chromite, etc. are used because they do not have a phase conversion that causes
rapid expansion of the grains, as well as offering greater density, which cools the
metal faster and produces finer grain structures in the metal. Since they are not
metamorphic minerals, they do not have the polycrystals found in silica, and
subsequently do not form hazardous sub-micron sized particles.
1.6
With both methods, the sand mixture is packed around a pattern, forming a
mold cavity. If necessary, a temporary plug is placed in the sand and touching the
pattern in order to later form a channel into which the casting fluid can be poured.
Air-set molds are often formed with the help of a two-part mold having a top and
bottom part, termed the cope and drag. The sand mixture is tamped down as it is
added around the pattern, and the final mold assembly is sometimes vibrated to
compact the sand and fill any unwanted voids in the mold. Then the pattern is
removed along with the channel plug, leaving the mold cavity. The casting liquid
(typically molten metal) is then poured into the mold cavity. After the metal has
solidified and cooled, the casting is separated from the sand mold. There is typically
no mold release agent, and the mold is generally destroyed in the removal process.
The accuracy of the casting is limited by the type of sand and the molding process.
Sand castings made from coarse green sand impart a rough texture to the surface,
and this makes them easy to identify. Castings made from fine green sand can
shine as cast but are limited by the depth to width ratio of pockets in the pattern.
Air-set molds can produce castings with smoother surfaces than coarse green sand
but this method is primarily chosen when deep narrow pockets in the pattern are
necessary, due to the expense of the plastic used in the process. Air-set castings
can typically be easily identified by the burnt color on the surface. The castings are
typically shot blasted to remove that burnt color. Surfaces can also be later ground
and polished, for example when making a large bell. After molding, the casting is
covered with a residue of oxides, silicates and other compounds. This residue can
be removed by various means, such as grinding, or shot blasting.
During casting, some of the components of the sand mixture are lost in the thermal
casting process. Green sand can be reused after adjusting its composition to
replenish the lost moisture and additives. The pattern itself can be reused
indefinitely to produce new sand molds.
2.0 Forging
2.1 What is Forging
Forging is a
work
cast or
machined part. As the metal is shaped during the forging process, its internal
grain deforms to follow the general shape of the part. As a result, the grain is
continuous throughout the part, giving rise to a piece with improved strength
characteristics.
Some metals may be forged cold, but
forged. Hot forging prevents the
iron and
hot
2.3 Processes
There are different kinds of forging processes available, however they can be
grouped into three main classes:
Drawn out: length increases, cross-section decreases
Upset: length decreases, cross-section increases
Squeezed in closed compression dies: produces multidirectional flow
Common forging processes include: roll forging,
names imply, the difference is in the shape of the die, with the former not fully
enclosing the work piece, while the latter does.
impression-die forging. Impression-die press forging usually requires less draft than
drop forging and has better dimensional accuracy. Also, press forgings can often be
done in one closing of the dies, allowing for easy automation .
varying on the rate at which the material is cooled. The material is then often
tempered to reduce the brittleness that may increase from the quench hardening
process. Items that may be quenched include gears, shafts, and wear blocks.
2.5.1 Process
Quenching metals is a progression; the first step is soaking the metal, i.e. heating
it to the required temperature. Soaking can be done by air (air furnace), or a bath.
The soaking time in air furnaces should be 1 to 2 minutes for each millimeter of
cross-section. For a bath the time can range a little higher. The recommended time
allotment in salt or lead baths is 0 to 6 minutes. Uneven heating or overheating
should be avoided at all cost. Most materials are heated from anywhere to 815 to
900 C (1,500 to1,650 F).
The next item on the progression list is the cooling of the part. Water is one of the
most efficient quenching media where maximum hardness is acquired, but there is
a small chance that it may cause distortion and tiny cracking. When hardness can
be sacrificed, whale, cottonseed and mineral oils are used. These often tend to
oxidize and form a sludge, which consequently lowers the efficiency. The quenching
velocity (cooling rate) of oil is much less than water. Intermediate rates between
water and oil can be obtained with water containing 10-30% UCON from DOW, a
substance with an inverse solubility which therefore deposits on the object to slow
the rate of cooling.
To minimize distortion, long cylindrical workpieces are quenched vertically; flat
workpieces are quenched on edge; and thick sections should enter the bath
first. To prevent steam bubbles the bath is agitated.
2.5.2 Equipment
There are three types of furnaces that are commonly used in quench hardening:
salt bath furnace, continuous furnace, and box furnace. Each is used depending
on what other processes or types of quench hardening are being done on the
different material
CAREER EPISODE 2
Company : Bharat Heavy Electricals Limited
My Role : Industrial Training
Duration : 03 July 2005 16 July 2005
Bharat Heavy Electricals Ltd. (BHEL) is the largest engineering and
manufacturing enterprise of its kind in India and is one of the leading
international companies in the field of power equipment manufacture. The
first plant of BHEL, set up at Bhopal in 1956, signalled the dawn of the Heavy
Electrical Industry in India. In the sixties, three more major plants were set
up at Haridwar, Hyderabad and Tiruchirapalli that form the core of the
diversified product range, systems and services that BHEL offers today. The
industrial power prior to electrical grids. Now they are mostly used for
electric power generation. Water turbines are mostly found in Embankment
dams to generate electric power from water kinetic energy.
1.2.1.1 Types of Water Turbine
Reaction Turbines:
VLH
Francis
Kaplan, Propeller, Bulb, Tube, Straflo
Tyson
Gorlov
Impulse Turbine
Waterwheel
Pelton
Turgo
Crossflow (also known as the Michell-Banki or Ossberger turbine)
Jonval turbine
Reverse overshot water-wheel
Archimedes' screw turbine
The Francis turbine is a type of water turbine that was developed by James B.
Francis in Lowell, Massachusetts.[1] It is an inward-flow reaction turbine that
combines radial and axial flow concepts. Francis turbines are the most
common water turbine in use today. They operate in a water head from 33 to
123 feet (10 to 37 meters) and are primarily used for electrical power
production. The generators which most often use this type of turbine, have a
power output which generally ranges from 10 to 750 megawatts, though
mini-hydro installations may be lower. Penstock (input pipes) diameters are
between 3 and 33 feet (0.91 and 10.06 metres). The speed range of the
turbine is from 83 to 1000 rpm. Wicket gates around the outside of the
turbine's rotating runner control the rate of water flow through the turbine
for different power production rates. Francis turbines are almost always
mounted with the shaft vertical to keep water away from the attached
generator and to facilitate installation and maintenance access to it and the
turbine
automatically
adjusted
propeller
blades
with
automatically
adjusted wicket gates to achieve efficiency over a wide range of flow and
water level. The Kaplan turbine was an evolution of the Francis turbine. Its
invention allowed efficient power production in low-head applications that
was not possible with Francis turbines. The head ranges from 1070 meters
and the output from 5 to 200 MW. Runner diameters are between 2 and 11
meters. The range of the turbine rotation is from 79 to 429 rpm. The Kaplan
turbine installation believed to generate the most power from its nominal
head of 34.65m is as of 2013 the Tocoma Power Plant (Venezuela) Kaplan
turbine generating 235MW with each of ten 4.8m diameter runners.
Turgo
turbine
is
an
impulse
water
turbine
designed
for
medium
three decades
Dedicated shop area of over 100000 sq. meters.
Ultramodern model development and testing facilities.
Sophisticated CAD/CAM facilities.
ISO 9001 Certification.
ASME "Q" stamp for fabrication facilities.
5. .Gov. Assembly
Regulators,
Associated
auxiliaries
and
station
equipment.
Rating (No.xmw)
4500
6 X 165
320
100
166.7
4550
3 X 135
304
300
3850
8 X 125
60
5000
Ranganadi
2400
Indira Sagar
115.4
5650
7000
Kalinadi
6 X 135
350
375
3072
2060
1.5~300
Head(m)
200~1500
Runner Diameter(mm)
1000~5000
No. of Units
Orders 46 1501 MW
Commissioned 30 788 MW
Rating (No.xmw)
Head (m)
Speed (rpm)
Varahi
2 X 115
460
250
4500
Sharavathy
2 X 89
440
300
3680
Chukha
4 X 84
435
300
3680
Tilari
1 X 60
625
500
2640
Bhabha
3 X 40
887
500
2960
Malana
Pykara
2 X 43
3 X 50
480
1026
500
600
2300
2665
Turning
Drilling
Boring
Facing
Milling
2.1.1 Turning
Turning is a machining process in which a cutting tool, typically a non-rotary tool bit,
describes a helical toolpath by moving more or less linearly while the workpiece
rotates.
2.1.2 Drilling
The operation of making round holes in metal pieces is known as drilling.It is done
with the help of drilling machine.
2.1.3 Boring
Enlarging or smoothing an existing hole created by drilling, moulding etc.i.e. the
machining of internal cylindrical forms (generating) a) by mounting workpiece to the
spindle via a chuck or faceplate b) by mounting workpiece onto the cross slide and
placing cutting tool into the chuck. This work is suitable for castings that are to
awkward to mount in the face plate. On long bed lathes large workpiece can be
bolted to a fixture on the bed and a shaft passed between two lugs on the
workpiece and these lugs can be bored out to size. A limited application but one
that is available to the skilled turner/machinist.
2.1.4 Facing
It is part of the turning process. It involves moving the cutting tool at right angles to
the axis of rotation of the rotating workpiece. This can be performed by the
operation of the cross-slide, if one is fitted, as distinct from the longitudinal feed
(turning). It is frequently the first operation performed in the production of the
workpiece, and often the last- hence the phrase "ending up".
2.1.5 Milling
Milling (grinding), the process of grinding grain or other materials in a mill. Milling
machine, a cutting and shaping equipment removing asphalt pavement with a
milling machine Photochemical milling (disambiguation) a part of the leather
crusting process.
Parts of Lathe
1. Legs : A lathe may or may not have a stand (or legs), which sits on the floor and
elevates the lathe bed to a working height. Some lathes are small and sit on a
workbench or table, and do not have a stand.
2. Bed : Almost all lathes have a "bed", which is (almost always) a horizontal beam
(although some CNC lathes have a vertical beam for a bed to ensure that swarf, or
chips, falls free of the bed).
3. Headstock : At one end of the bed (almost always the left, as the operator faces
the lathe) is a "headstock". The headstock contains high-precision spinning
bearings.
4. Spindle : Rotating within the bearings is a horizontal axle, with an axis parallel
to the bed, called the "spindle". Spindles are often hollow, and have exterior threads
and/or an interior Morse taper on the "inboard" (i.e., facing to the right / towards the
bed) by which accessories which hold the workpiece may be mounted to the
spindle. Spindles may also have exterior threads and/or an interior taper at their
"outboard" (i.e., facing away from the bed) end, and/or may have a handwheel or
other accessory mechanism on their outboard end. Spindles are powered, and
impart motion to the workpiece.The spindle is driven, either by foot power from a
treadle and flywheel or by a belt drive to a power source. In some modern lathes
this power source is an integral electric motor, often either in the headstock, to the
left of the headstock, or beneath the headstock, concealed in the stand.
5. Tailstock : The counterpoint to the headstock is the tailstock, sometimes
referred to as the loose head, as it can be positioned at any convenient point on the
bed, by undoing a locking nut, sliding it to the required area, and then relocking it.
The tailstock contains a barrel which does not rotate, but can slide in and out
parallel to the axis of the bed, and directly in line with the headstock spindle. The
barrel is hollow, and usually contains a taper to facilitate the gripping of various
type of tooling. Its most common uses are to hold a hardened steel centre, which is
used to support long thin shafts while turning, or to hold drill bits for drilling axial
holes in the work piece. Many other uses are possible.
6. Cross slide : Metalworking lathes have a "cross slide", which is a flat piece that
sits crosswise on the bed, and can be cranked at right angles to the bed. Sitting
atop the cross slide is a toolpost, which holds a cutting tool which removes material
from the workpiece. There may or may not be a leadscrew, which moves the cross
slide along the bed
Milling machines can perform a vast number of operations, some of them with quite
complex toolpaths, such as slot cutting, planing, drilling, diesinking, rebating,
routing, etc.
Cutting fluid is often pumped to the cutting site to cool and lubricate the cut, and to
sluice away the resulting swarf.
Less effort is required to apply the drill to the workpiece. The movement of
the chuck and spindle is by a lever working on a rack and pinion, which gives
the operator considerable mechanical advantage.
The table allows a vice or clamp to position and lock the work in place making
the operation much more secure.
The angle of the spindle is fixed in relation to the table, allowing holes to be
drilled accurately and repetitively.
A horizontal boring machine or horizontal boring mill is a machine tool which bores
holes in a horizontal direction. There are three main types table, planer and floor.
The table type is the most common and, as it is the most versatile, it is also known
as
the
universal
type.
A horizontal boring machine has its work spindle parallel to the ground and work
table. Typically there are 3 linear axes in which the tool head and part move.
Convention dictates that the main axis that drives the part towards the work spindle
is the Z axis, with a cross-traversing X axis and a vertically traversing Y axis. The
work spindle is referred to as the C axis and, if a rotary table is incorporated, its
centre line is the B axis.
Horizontal boring machines are often heavy-duty industrial machines used for
roughing out large components but there are high-precision models too. Modern
machines use advanced CNC control systems and techniques.
200mm
10500mm
5000mm
31503150
Resistive spot welding (RSW) is a process in which contacting metal surfaces are
joined by the heat obtained from resistance to electric current.
Work-pieces are held together under pressure exerted by electrodes. Typically the
sheets are in the 0.5 to 3 mm (0.020 to 0.118 in) thickness range. The process uses
two shaped copper alloy electrodes to concentrate welding current into a small
"spot" and to simultaneously clamp the sheets together. Forcing a large current
through the spot will melt the metal and form the weld. The attractive feature of
spot welding is that a lot of energy can be delivered to the spot in a very short time
(approximately 10100 milliseconds). That permits the welding to occur without
excessive heating of the remainder of the sheet.
CAREER EPISODE 3
Company : Sigma Heavy Engineering Limited
My Role : Industrial Training
Duration : 1 June 2004 30 June 2004
beams and
angles.
c) A 800 ton hydraulic bending and 400 ton press and a 250 ton friction press
are
used for cold and hot bending from rolled sheets and shapes. Parts to
bend are
pre heated
c) Some components and units undergo only prime coating in the steel
structure section, with subsequent painting in the painting section of the
machine and assembly section.
Torches that do not mix pure oxygen with the fuel inside the torch, but burn it with
atmospheric air, are not oxy-fuel torches and can be identified by their single tank.
(Oxy-fuel welding/cutting needs two tanks, fuel and oxygen.) Most metals cannot be
melted with such single-tank torches, so they can only be used for soldering and
brazing, not welding.
1.8 Planers
A planer is a type of metalworking machine tool that is analogous to a shaper, but
larger, and with the entire workpiece moving beneath the cutter, instead of the
cutter moving above a stationary workpiece. The work table is moved back and
forth on the bed beneath the cutting head either by mechanical means, such as a
rack and pinion gear, or by a hydraulic cylinder.
Planers and shapers were used generally for two types of work: generating accurate
flat surfaces and cutting slots (such as keyways). Planers and shapers are now
obsolescent, because milling machines have eclipsed them as the machine tools of
choice for doing such work.
Cutting Methods: Plasma cutters have also been used in CNC machinery.
Manufacturers build CNC cutting tables, some with the cutter built in to the table.
The idea behind CNC tables is to allow a computer to control the torch head making
clean sharp cuts. Modern CNC plasma equipment is capable of multi-axis cutting of
thick material, allowing opportunities for complex welding seams on CNC welding
equipment that is not possible otherwise.
1.11.2 Radiography
In this test the X-rays and gamma rays are used to detect deep seated internal
defects. The short wavelengths of X-ray permitted to penetrate through the opaque
material. Gamma rays are the electro-magnetic radiations that are emitted from an
unstable nucleus.