144 Mechanics of Chip Formation Metal cutting is accompanied by extensive plastic deformation and fracture between the workpiece surface and tool face. — The mechanics of chip formation can be explained with the help of diagram shown in Fig. 1.1.1. — Im the machining process, the metal is being forced off the workpiece by compression, sheating and then slides along the rack, face of the tool. = The chip formation is a localized shear process in a narrow region where the metal is compressed and then made to flow on the face of the tool. = When the tool advances in the workpiece, heavy forces are exerted on the face of the workpiece which is in contact with the tool face. ; + The material is cut when the maximum stress is exerted along the shear plane as shown in Fig. 1.1.1. — Achip is produced ahead of cutting tool by deforming and the shearing the material continuously along the shear plant. This plane is at an angle with the workpiece surface, The angle between the rack face and normal to workpiece is rake angle. It is denoted by a. It may be positive or negative. Cutting toot Tool motion = Shear plane Fig. Lda 1.1.2.1, Tool Signature D_(USBTE -W-10, W-19, S:12WH2, 515,549 ‘What is tool signature? Explain tool signature. ; ‘What is tool signature ? Why itis necessary ? Explain tool signature with suitable example, ~ Acconvenient way to specify tool angles is by use of a stindardized abbreviated system known as tool signature, Tie tool signature describes as to how the tool is positioned in relation to the workpiece. Hille = A rypical tool signature is always given in a definite order as shown below: Tool signature -0-7-7-7-15- 15-08 — It means that back rake 0°, Side rake 7°, End relief 7°, Side relief 7°, End cutting edge angle 15°, Side cutting edge angle 15°, Nose radius 0.8 mm. = Factor affecting the rake angle of the single point cutting tool Factors affecting the rake angle of the single point cutting tool are as follows. Type of workpiece material If the work material has low yield strength the rake angles may be increased or if the work material has higher yield strength the rake angles may be decreased. Hard materials like cast iron can be machined with smaller rake angle. (1) Type of too} material Tools made from very hard and brittle materials are having negative rake angles where as tools made from high s* steel] has positive rake angles. (IM) The rake angle may be increased in negative direction when cutting edge strength is required, | (IV) The rake angle may be increased in the positive direction when either workpiece or machine have the poor rsii dl1A. Y a, 4 Types of Chips it it indication of quality of cuin, it fon of chips. The chips are the in : i in always results in formation of Conventional machining process operation applied also. ‘The type of chips determines the narure and properties of material, mensional accuracy of the job. iting forces, temperature developed and tn most ofthe machining operations, there are three types of chips are observed. Those are as follows. Continuous chips Gi) Discontinuous chips (Gi) Continuous chips with built up edge. Continuous chips = When ductile materials like aluminum, mild steel, copper etc. are machined, long continuous ribbon type chip is formed. = Because of its form in continuous segment, is called as continuous chip. = These are the chips which undergo continuous plastic deformation ahead of the cutting edge. These chips are formed generally at higher cutting speeds. = Almost they have equal thickness throughout is length, they $ generally leaves good surface finish. Fig. 1.14(a) shows (© Chip with builtup edge continuous ype of chips. Fig 1.1.4 Discontinuous chips ~ When hard and brittle materials like cast iron, brass and bronze are machined under lower cutting speeds discontinuous chips are formed. ‘The small pieces of discontinuous chips either separated or loosely connected to each other, A series of fractut ‘curs to form these chips. ' er ‘on in fk nl Continuous breaking of chips causes the reduction in friction between tool and chips. These are easy to handle At slower cutting speeds, the format ra tool wear. For ion of discontinuous chips results in poot i 7 ‘brittle materials, surface finish is better,» a ~ Fig. 1.1.40) shows discontinuous chips,wa ‘Thread cutting Q. Explain thread cutting operation on lathe machine. ‘operation helical groves are produced by fading the tool along the job axis. Fig. 1.2.18 shows thread cutting operation. D> (MSBTE - S-16, W-16) ] Producing threads of different diameters and pitches on cylindrical jobs is called thread cutting operation. In this 7 Workeace Ny aN Threading V-00! Fig. 1.2.18 : Thread CuttingW_Manutacturing Processes (MSBTE-Sem 4-Mech) 1. 1 Fundamental of Machinin 1d Machining Operations { @.__ State the various operations performed on driling machine. Explain any one, a ‘The different operations that can be performed in a drilling machine are : ‘4, Counter boring 6. Countersinking Fig. 1.3.5 : Drilling machine operations > 1 Drilling ~ Drilling is the operation of a cylindrical hole by removing metal by the rotating edge of a cutting tool called the drill. - The drilling is one of the simplest methods of producing a hole. — Before drilling the center of the hole is marked on the workpiece by drawing two lines at right angles to each other and then a center punch is used to produce Wo" an indentation at the center. rkplece (@) Drilling operation (b) Reaming operation Fig. 1.3.6 ‘The drill point is pressed at this center point to produce the required hole. The intemal surface of the hole so generated by drilling becomes rough and the hole is always slightly oversize than the drill used due to the vibration of the spindle and the drill. ~The working principle of drilling or drilling operation is shown in Fig. 1.3.6(a)> Git) Taper turning pppppeo Ege tate > (MSBTE -8-09, W-10, W-12, W-14, 5-15, W-15,515.51 Name the taper turning methods on lathe. Explain any ono. State the methods of taper tuming on lathe. Explain any ono with neat sketch. Explain taper tuming operation on lathe with suitable example. ‘State the methods of taper tuming on lathe. TEE Ge bs TEX Define taper. Explain taper angle calculation with neat sketch. State the four methods of taper tuming on lathe. EX} Taper tuning produces a taper along the axis of thie workpiece. Tapers are produced by either offsetting the tails from centerline or by using a “taper attachment”. Some short, steep tapers can be obtained by using the compound rest alo © Taper turning methods Ina lathe, the taper can be turned by any one of the following methods : Taper turning methods, (i) Swiveling of the compound rest (ii) Setting over the tailstock centre | (ii) By using broad nose form tool (iv) By a taper turning attachment Fig. 1.2.13 : Taper turning methods2.1.3 Classification of Shapers ea Q. List the types of shaping machines OR Classify shaping machines. Shapers can be classified under different categories as follows.W Men (@ According tothe driving mechanism of ram wufacturing Processes (MSBTE-Sem 4-Mech) 23 Shaping / Slotting Machi () Crank type shaper (ii)-—-Hydraulic type shaper (iii) Geared type shaper (@) According to position and travel of the ram (@ Horizontal shaper Gii)_—_-Vertical shaper (iii) Travelling head shaper (6) According to the design of table (@) Standard shaper Gi) Universal shaper (@ According to the movement of cutting stroke (i) Push type shaper (ii) Draw cut type shaper eepa Quick Return Mechanism ‘ Q Explain qui return motion mechanism used in shaper with neat sketch. | A quick return mechanism is a mechanism that converts rotary motion into reciprocating motion at different rate for its two strokes,~ The time required for cutting stroke is greater than time for return stroke ie. retum stroke is faster than working stroke sois called quick return motion mechanism. It is also known as crank and slotted lever mechanism. . ~ Fig. 2.2.1 shows cutting stroke angle o and return stroke angle B.Here stroke length is BC. ZDA,A, = B ZA,0A, = 0 BC = Stoke length ~ Fig. 2.2.2 shows type of quick retum mechanism. Clamping lever Adjustment of Catting stroke stroke Return stoke ‘Stroke length Rocker arm. Fig. 2.2.1 : Quick return mechanism Fig. 2.2.2 : Crank and slotted lever mechanism ~ In this mechanism, power is given to the driving pnion through an individual motor or by some other mechanism, Driving pnion thus transmits the motion to the large bull gear mounted within the column. The speed of the bull gear can be varied. The radial slide is bolted to the centre asthe bull gear. ‘o'is the centre ofthe bull gear, ~ A slotted lever having a long slot along its length is pivoted about point. ~ _Asliding block is fitted inside the slot and slides along the length of the slotted link. A is the crank pin, the slotted bar is also known as rocker arm. A ram is fitted to rocker arm through ram block. ~ Ram block can be fastened on the screwed shaft with the help of clamping lever, Working ~ As the bull gear rotates, the crank pin revolves at a uniform speed. The sliding piston block also rotates on crank pin circle. The sliding block which slides along the slot in the rocker arm at the same time, ~The movement of slotted bar is transferred to ram, which moves forward and backward, as per the rotation of crank. Stroke length QR is proportional to the crank length OA. It can be adjusted with the help of lead serew in the crank ie.7 4.4 Basic Parts of Slotting Machine and their Functions ,__List the parts of slotter or slotting machine, ] Toot head Toot Table Crossstide Fig. 2.4.2 Basic Parts of Slotting Machine and their Functions General block diagram of slotting machine is shown in Fig. 2.4.2, The principle parts of slotting machine are as follows : @ Base Gi) Column (iii) Table, Gv) ‘Saddle () cross slide (vi) Ram (vii) Tool head (viii) Ram drive mechanismManufacturing Processes (MSBTE-Sem 4-Mech) Shaping / Slotting Macting — Fig. 2.1.1 shows working principle of shaping machine, In this process, work is rigidly held in a vice. The cutting toi held in the tool post mounted on the ram of the machine. The ram reciprocates forward and backward in a straight lire Job is fed across the cutting motion of the tool. cut utting motion, - Feed motion and cutting motions are perpendicular to each other. As the ram reciprocates, the tool cuts the material in the forward stroke. It is also called cutting stroke. During retum Stroke, no metal is cut, so the stroke is called'idle stroke. It is also called cutting stroke. During return stroke, the cutting and return stroke forms one operating cycle of shaper. Fig. 2.1.1 : Working principle of shaper3.3.1 Types of Moulding Sands ‘ > (MSBTE - W-14, W-17) Q. State different types of moulding sands. Q. Explain green sand mouiding. Following are the types of moulding sands ‘Types of moulding sands , 1. Green sand 2. Dry sand 3 Facing sand 4. Backing and 5. Parting sand 6. Core sand HE Fig. 3.3.1 : Types of moulding sandsSyllabus Topic : Elemente of Gating System p35 Elements of Gating System > (MSBTE - 8-14, W-15, $16) EES) @.__Explain various elements of gating system in casting process, A gating system is a arrangement in which different Clements are present in the form of channels, by means of which molten metal is delivered to the mould a /csaore ae cavity. A gating system comprises all those channels Tarte Spruo —_|: Which are connected with the flow of molten metal 5 By : from the ladle to the mould cavity. Parting Hence, the molten metal is not poured directly into the mould, but it is introduced through the gating system. Runner 2 \ Mould cavity and gate Fig. 3.3.5 shows components of gating system. Fig. 3.35 : Elements of gating system‘Syllabus Topic : Calendaring Pst Calendaring D (MSBTE - W-10, S-12, S-14, W-17, S19) Se W10) W-17)S-18) @. Explain calendaring with neat sketch: State the two product manutactured by : Calendaring. Bo ‘What Is calendering operation in plastic processing? Write two application: Itis an important method for making of films and sheets. Calendaring is a finishing process applied to textiles and paper. During calendaring, rolls of the material are passed between several Pairs of heated rollers, to give a shiny surface. Extruded PVC sheeting is produced in this manner as well other plastics. Calendaring is a final process in which heat and pressure are applied to a fabric by passing it between heated rollers, imparting a Conveyor belt flat, glossy, smooth surface. Fig. 3.6.3 : CalendaringW. Manufacturing Processes (MSBTE-Sem 4-Mech) 3-43 Casting Processes and Plastic Moulding Laster increases when the degree of heat and pressure is increased. — Fig. 3.6.3 shows calendaring process. Applications Flexible PVC products like rainware, shower curtains, etc and rigid PVC products like trays, laminates and credit c: ete. — Floor tiles from vinyl, cellulose acetate sheets and films. 0 ‘Syllabus Topic : Plastic Moulding Methods : Compression moulding, Injection moulding, Blow moulding and ExtrusionHig. 3.3.7: Jolt machine _ Syllabus Tople : Casting : Safety Practices/Precautions In Foonioron —_—_S— er iittceerPreceutions In Foundry ahop 3.4 Casting ‘ ‘The definition of asting and major steps of casting are already piven in the beginning of the wp = Inthis ance, the different furnaces used for casting process, methods of casting with applications are covered. _AAd Safety Practices/Precautlons In Foundry shop In foundary shop, the work environment is hot due to burns and fires around furnaces and crucibles. Dust and fumes ration is common phenomenon, Workers should follow safety practices as mentioned below. They should get proper training on work techniques. (i) Use personal protective equipments like leather shoes, glores, safety glasses to get protection from foundary environment. (i) Inspect foundary equipments on a frequent basis for cracks and signs of wear.W__Manufacturing Processes (MSBTE-Sem 4-Mech) 3-20 Casting Processes and Plastic Mo Gii) Do not try to expose the water to the furnace or crucible as it can cause large explosion. (iv) Keep the work area clean and clear as the molten metal which is spilled out can spread over a great distance. (v) Pouring and melting must use non-flammable surfaces such as metal or sand. (vi) Provision of good ventilization is must in foundary shop. (vii) Use dust control measures like non toxic binding materials to control silica dust. (viii) Use medically approved respiratory kit. CS Syllabus Topi SSS9.4.3.1. Centrifugal Casting D> (MSBTE - W-14, S-15,W-17, S-18) .@. Explain contritugal casting with neat sketch, Centrifugal casting is a process in which molten metal is poured and allowed to solidify while the mould is kept revolving. Due to rotation of mould, the poured metal is subjected to centrifugal force. Due to centrifugal force, the poured metal flows in mould cavities. The solidification progresses from periphery to Moule centre as the more dense metal deposits to-the outer side of casting, “ Sand : LLZZZZELLLLLLLLA ining and segregates towards the centre. In this process the use of gates, oO € feeders and cores is eliminated. Casting ~The lighter slag, oxides and inclusions gets separated from the metal LLL ~The axis of ratation is usually horizontal but can be vertical for short work pieces. Fig. 3.4.5 shows centrifugal casting operation. Centrifugal casting is best suitable in mass production operation. Roters Fig. 3.4.5 : Centrifugal castingManufacturing Processes (MSBTE-Sem 4-Mech) 3.26 Casting Processes and Plastic Mo ‘Some of the common casting defects found in castings with their causes and remedies are explained below : — 6. Cold shut Fig. 3.4.8 : Casting Defects~ 3.4.2, Furnaces ‘> (MSBTE - S-14, S-15, W-15, W-16, Sag Q. Classity melting tumace in casting process. SEE ©... Explain construction and working of Cupola furnace with neat sketch. ~ A furnace miay be defined as a refractory lined chamber in which metal is heated to the desired temperature. Ithas a boy like structure made of steel. ~ _ Reonsists of access door, a refractory lining, temperature controls and indicators. P 3.4.2.1. Types of Furnace ‘Melting furnaces used in the foundry are various types. The selection of the suitable furnace is a crucial decision is the casting process. ‘The factors responsible for selection of furnace are : (@) The temperature required to melt the metal or alloy. (©) Rate of melting alloy and quantity of molten metal required. (©) Type of metal to be melted. (@) Economic considerations. Following are the most commonly used furnace in the industry : 2. Ollor gas fred furnaces 3 Crucibe furnaces 4, Electric are furnaces: ‘5, Induction furnaces Fig. 3.4.1 : Types of furnaceSeeia-*** O51 E-Som 44 : ¥ Mech) 3-21 Casting Processes and Plastic Moulding _— Syllabus Topic : Construction and Working of Cupola Furnace (1) Cupola furnace > (MSBTE- 5-14, w-15, W-17, $18) ~ _Itis the most commonly employed furnace for melting and further refining pig iron along with scrap for production of castings. ~ Cupola is available in different sizes and is easy to operate. It is one of the fastest melting furnace. Construction ~ Fig. 3.4.2 shows construction of cupola furnace. It is a refractory lined vertical cylinder, open at both its top and bottom, ‘The raw material and fuel are charged at the top. ~ Its diameter usually varies from 1 to 2 meters and the height varies from 4 to 5 times the diameter. Refractory lining F Stack ‘Charging ~, door Charging floor IPraheating [Melting ICombuton Wind box Tuyere openings: Well . Tap hole Slag hole ‘Sand bottom Drop door Fig. 3.4.2 Cupola cross section ~ The foundation is made of bricks, concrete and fire brick columns are the provided to"support it, The bottom door ‘emains hinged on legs. Air for combustion comes from a blower through the blast pipe which enters in wind box ‘Completely surrounding the cupola itself. ‘Tuyeres are the openings that take air from wind box and delivers ito the combustion zone of the cupola.Manufacturing Processes (MSBTE-Sem Casting Processes and Plastic Moulin, Working © _ In the beginning of a melt, a sand bottom is first rammed upon the drop-bottom. Gi) Cupola is fired with fuels like wood and layer of coke is put on the sand bottom. (ii) Charges of pig iron, scrap, flux and coke are mixed and kept within the furnace on the burning coke in alternate layers. (iy) Once the cupola is fully charged, itis maintained as such for about half to one hour. This gives proper soaking to meta \ ng, sir blower is started and the slag door is opened to allow the slag to go out. (vi) When sutficient quantity of molten metal is collected over the sand bed, it is then periodically tapped into the ladles. Syllabus Topic : Electric Arc Furnace7/438 Applications D> (MSBTE -s-15) ain au Ea] (@)_ The extrusion process is mostly employed on non-ferrous metals like aluminum, copper, magnesium etc. Gi) Production of seamless tubes made from special alloy steels. (iii) Variety of cross-sectional shapes such as circular, square, rectangular, hexagonal etc. either in solid or hollow form. (iv) Channel sections, I-section, Z-section, T-section, etc. (¥) Tubes and pipes of complex configuration. Chapter Ends. aadZé 1 Open Die Forging D> (MSBTE - W-15, W.17 Q. Describe the open die forging with neat sketch. E Q. Explain the open die forging with neat sketch. [w17] ‘Open die forging is also called as flat die or hammer forging. It may be done by hand or by using power hammers. In open die forging, the working surface of both the upper an ower dies are flat and horizontal. The heavy falling weight of the hammer is called the ram and the rigid support is called the anvil block. Upper die is fitted to the bottom of the ram and the lower die is fitted on the top of the anvil. Fig. 4.1.5 shows open die forging.the workpiece is kept in between Upper die and lower di in die. ‘The shape is given to metal by falling the weight i, Th é Fam, force on ram is depend on height and velocity of the fal ° Number of blows are required to give final shape to metal. workpiece may be moved in between the blows to give the “rpc final shape. Work piece” Lower dio Hammers used are mechanical, air and steam hammers. (Fined) _ Open die forging is a traditional method of forging. Anvil block advantages , @) Itmakes the use of relatively simple tooling. Fig. 4.1.5 : Open die forging {@ Open die forging is relatively inexpensive. (i) Large variety in shapes can be produced. (iv) The shapes mostly forged are bars or slabs of circular, rectangular, hexagonal cross sections. () Mainly used for repair or maintenance work. Umitations Itproduces forgings with lesser accuracy than closed die forging. (i) Accuracy depends upon the skill of operator ( tis suitable for small production lot. 4) Open die forging is limited to simple shapes. ~ Syllabus Tople : Closed Die Forging ——— * Closed Die Forging > (wsBTe - w-14) Explain closed di forging with neat sketch. Closed die forging is also called as impression ae forging. In this type of forging, cavies in the form of impressions ie forging is al ‘We cut in the die block. ji impressi ind on the product. Dies used may be single impression oF mult Pre sion depe! pear ‘The closed dies are carefully machined matching blocks so as to produce forgings of accurate dimensions. ies are Fig. 4.1.6 shows closed die forging operation.Manufacturing Processes (MSBTE-Sem 4-Mech) 4.6 Forming Pro — The operation consists of placing the piece of heated metal on the lower die block. ‘The metal is forced to take its final shape and dimensions of the die by blow from a machine hammer, Half of the die is called lower die is. mounted on the anvil and Work pice other half ic. upper die is on the hammer. Lower die During the forging, the cavities in the dies are completely filled. (Fes) — Excess metal is squeezed or escaped out in the form of thin fin or flash. ‘Anvil Block — All forging operations are performed in the single die block. Fig. 4.1.6 : Closed die forging Advantages (@__ Itis successfully applied to produce complex shapes. (i) Large quantities of similar type with greater accuracy can be produced. Gii) It does not require high skilled operator. Gv) Closed die forging takes less time than open die forging. (v)_Itis suitable for mass production, Limitations @) Tooling cost is high. Gi) Not economical when quantity of products is small. Giiy Proper care should be taken determining amount of material to be inserted inthe die.4.2.2 Hot Rolling ~ In hot rolling process, the metal in a hot plastic state is passed between two rolls revolving at the same speed but in opposite direction. ~ As the metal passes through the roll, itis reduced in thickness and increased in length. ~The metal provided for hot rolling fist cast into ingots of suitable form i. rectangular, square or round. These ingots then heated in ges fired furnace to attain uniform working temperature. — Then these ingots are taken to rolling mills for hot rolling processes. — The flow of metal during rolling is continuous and almost in longitudinal direction. — Hot rolling produces components like plates, bars, sheets, wide variety of bars and sections, rods and other structural shapes. Syllabus Topic 9 rg 4.2.3 Cold Rolling = ~ Cold rolling is a finishing operation generally performed on products of hot rolling to give good surface finish, dimensional accuracy and strength of material. — Bars of different shapes, sheets, rods, strips produced by hot rolling are commonly finished by cold rolling process. ~ Cold rolling is done below the recrystallisation temperature of the metal. ~The operation consists of cleaning the stock in the form of sheet or strip in acid solution to remove scale. ~ Next step is to wash in water and then dried. This cleaned metal is then passed through set of rolls, ~ _Ineach pass, there is slight reduction in area. The process is repeated until the required thickness is obtained.‘Manufacturing Processes (MSBTE-Sem 4/ w jem 4-Mech) 43 Forming Processes ee Syllabus Toplc : Upset Forging OOo —————— 44.2. Upset Forging 7 > (useTe-w-17) jin upset forging With neat sketch, ] = Upset forging is also called machine forging. It involves the upsetting operation. = _Inthis type of forging metal is pressed and gathered either at the centre or only at one end. = Upsetting machines called upsetters are generally horizontal acting i.e. it appears in a horizontal direction. = Fig. 4.1.2 shows upset forging operation. It consists of applying length wise pressure to a bar of uniform section. = The bar or job is gripped in the fixed half of the die. The pressure is applied at the heated end thus causing it to be upset. = The heated end is placed between fixed and movable die which grips the bar firmly when closed. In this method the metal is displaced from the interior and made to flow around the outside of bar. Horizontal forging machines are specified by the diameter of bar that can be shaped. = After the operation, movable die and punch are withdrawn to their initial position. Advantages: @ Rate of production is high. (ii) Very little amount of flash is required. (ii) Quality of forgings comparatively better. Gv) Maintenance cost is low as compared to drop hammers. Umitations @) Most ofthe times, single pass is not sufficient to get the final shape. Gi) Difficult to handle heavy jobs.a rn emeeemeeeeeeemeeeememmeeneeeememe een eeeeeeneeeeeReRRRRERRERRRURERREEEEEEE ot 753s Applications D> (MSBTE-s-15) ‘Q.__ State applications of extrusion process. _ @_ The extrusion process is mostly employed on non-ferrous metals like aluminum, copper, magnesium etc. (ii) Production of seamless tubes made from special alloy steels. Gi) Variety of cross-sectional shapes such as circular, square, rectangular, hexagonal etc, either in solid or hollow form. (iv) Channel sections, I-section, Z-section, T-section, etc, (v)_ Tubes and pipes of complex configuration, Chapter Ends. gga¢ Wr Manufacturing ‘Syllabus Topic : Direct Extrusion. 4.3.1. Direct Extrusion Processes (MSBTE-Sem 4-Mech) > (MSBTE - S-14, W-14, S-15, W-15, W217, S18) Draw neat sketch of direct extrusion and explain its working. What is direct extrusion process? Describe with neat sketch. Describe the forward extrusion process with neat sketch. Explain direct extrusion. With neat sketch explain direct extrusion process. ppeee = Ibis also known as forward extrusion. Direct extrusion process is shown in Fig. 4.3.2. — Flow of metal through the die and movement of ram are in the same Lexrudes - A dummy block is placed between the hot metal and ram. As the paiel piston moves, the metal first deforms and fills the container shape. ‘Container or Ram Dummy block cylinder — As the pressure increases, itis then forced out through the die opening, producing a extruded product. Fig. 43.2 : Direct extrusion = The process contneous unl a small amount of metal remains inthe cylinder. Finally itis then cutoff at the die opening and the process. completes. — Direct extrusion is « popular method as the process is very simple. Syllabus Topic : Indirect Extrusion 4.3.2 Indirect Extrusion > (MSBTE- 8-14, w. + S-14, W-14,S-16, W-16) Q._Describe “Backward Extrusion Process” with neat sketch. EEE cylinder Extruded part Closed end Hollow ram Fig. 433 : Indirect Extrusion — _ Ttis also known as backward extrusion. In this process, the metal flows in the opposi av pPosite direction of ‘The ram inthis process is a hollow one. The die is mounted over the hollow ram as sh one own in Fig. 4.3.3,WW Manufacturing Processes (MSBTE-Sem4-Mech) 4.17 Forming Processes In indirect extrusion billet is extruded by the hollow ram which is also referred as punch. ‘The die is attached to the ram, thus pushed into the billet which is stationary inside the container. During the process there is no friction between the metal billet and the cylinder walls, Extrusion force required is less as compared to direct extrusion but the press machine is somewhat complicated as ‘compared to direct extrusion, As compared to direct extrusion, this method finds limited applications. Both the extrusion processes i. lirect and indirect may be done hot or cold depend on material. 4.3.3 Difference between Direct and Indirect Extrusion Process > (sete -s-15)woo J23 lanufacturing Processes (MSBTE-Sem Difference between Brazing and Soldering Q. Differentiate between brazing and soldering. Q. Differentiate between brazing and soldering. (any four points) filler metal whose melting point is above 400°,C but lower than base metal. Sr. Brazing Soldering No. (1) It is a process of joining two dis-similar metals by using Itis a method of joining similar or dis-similar metals 4 using filler metal whose liquidus temperature is below }400° C. a| Filler metals generally used are lead, tin etc. Filler is non ferrous metal or alloy i.e. copper, zine, aluminum ete. (@) | Filler are generally called as solders. Fillers are generally called as spelters. (4) | Relatively strong joint is produced. (Comparatively weak joint is produced. (5) [Brazing methods are torch brazing, fumace brazing, |Common soldering methods are soldering iron method resistance brazing ete. torch soldering furnace and hot plate ete. (© | Applications : Electrical connections, joints on PCB,etc. | Application : Pipe fittings, heat exchange joins, carid _ |tips on tools etc.= Comparison of TIG with MIG Welding MIG ok i) | Ituses non consumable type electrode Ituse consumable wire electrode. ii) _ | Electrodes are made of tungsten or its alloys | Metal wire electrode of desired composition. Electrode only generate an arc and does not melt Electrode generate an arc and melt itself. iii) [Above 4 mm thick plates can be welded. Widely used for thin plates iv)§¥_Manufacturing Processes (MSBTE-Sem4-Mech) 5-10 Joining Processes Sr.No. Tie MIG | v) | Used for joining dis-similar metals Used for joining similar metals. vi) _|Itis slow process but produces smooth weld {It is faster process. Syllabus Topic : Plasma Arc Welding_ fo) Laser Beam Welding (LBW) > (MSBTE- 5-15, 5-18) . Explain Laser Beam Welding with neat sketch. 5) @. Explain laser beam welding with neat sketch, : ~The word laser stands for light amplification by stimulated emission of radiation, ~ _Itis a concentrated beam of coherent monochromatic radiation, — The laser beam is a high energy source to heat and to melt the metals to be joined. The laser beam is-produced by capacitor discharge into xenon tubes. This intense light is directed to pass into ruby crystal doped with transistion elements, — The electrons in the ruby crystal are stimulated by this light source. They try to return to their normal energy level, releases extra energy of constant wavelength. i These radiations can be concentrated by optical lenses. - Ascompared to EBW ic. electron beam welding the method has following advantages. Advantages @_Itcan be done in air, no requirement of vacuum.WW Manutacturing Processes (MSBTE-Sem4-Mech) 5.16 IY Procnssn_ (i) Simple optical lenses for focusing the beam can serve the purpose. i) Welding inside plastic or glass encloser is possible, (iv) Deep penetration is possible upto the ratio of 4 = 200: 1.