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46 views8 pages

Assignment: Subject

Uploaded by

NAJAMUL Hassan
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as DOCX, PDF, TXT or read online on Scribd
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ASSIGNMENT

SUBJECT:
WORKSHOP PRACTICE

DEPARTMENT:
MECHANICAL ENGINEERING

SUBMITTED TO:

DR. ANEELA WAKEEL

SUBMITTED BY:
MUHAMMAD USAMA ZAHOOR

REG NO:
20-ME-11
FORGING
Forging a metal shaping technique using compressive, localized forces, has been a
staple metal fabrication technique. Forging is most commonly performed with the use of
forging presses or hammering tools that are powered by electricity, compressed air.
Different products which are formed by the process of forging process are:

 Crankshaft
 Camshaft gears
 Generator rotor
 Bolts

We will discuss the manufacturing process of Bolts:

MANUFACTURING PROCESS

1. Wire - Uncoiled, straightened and cut to length.


2. Cold forging - Molding the steel into the right shape at room temperature. The
grade of steel is standardized across the industry, according to the
requirements of ISO 898-1. Using special tooling, the wire is then cold forged
into the right shape. This is basically where the steel is molded, while at room
temperature, by forcing it through a series of dies at high pressure. The
tooling itself can be quite complex, containing up to 200 different parts with
tolerances of hundredths of a millimeter. Once perfected, cold forging ensures
bolts can be produced quickly, in large volumes, and with high uniformity.
3. Bolt head - Progressively formed by forcing the steel into various dies at high
pressure.
4. Threading - Threads are formed by rolling or cutting.
5. Heat treatment - The bolt is exposed to extreme heat to harden steel.
6. Surface treatment - It depends on the application. Zinc-plating is common to
increase corrosion resistance.
7. Packing/stocking - After quality control to ensure uniformity and consistency,
the bolts are packaged.

WELDING
Welding is a materials joining process which produces coalescence of materials by heating them to
suitable temperatures with or without the application of pressure or by the application of pressure
alone, and with or without the use of filler material.

Applications of welding:
Railway wagons, machine frames, structural works, tanks, furniture, boilers, general repair work and
ship building.

PROCESS OF WELDING
Cleanup is usually necessary.

A replaceable electrode “stick” also serves the role of filler metal. An arc is created that
connects from the end of the stick to the base metals, melting the electrode into filler
metal and creating the weld.

The stick is coated in flux that creates a gas cloud when heated up and protects the
metal from oxidation.

As it cools, the gas settles on the metal and becomes slag.

Since it doesn’t require gas, this process can be used outdoors, even in adverse
weather such as rain and wind.

It also works well on rusted, painted, and dirty surfaces, making it great for equipment
repairs. Different types of electrodes are available and easy to swap, making it simple to
weld metals of many different kinds, though it’s not great for thin metals.

Stick welding is a highly skilled process with a long learning curve.


BRAZING
Brazing is a process of joining two pieces of metal in which a non-
ferrous alloy is introduced in a liquid state between the pieces of
metal to joining allowed to solidify.

The melting temperature of the filler material is about 600°c, but lower


than the melting temperature of the parent metal. The filler metal is
distributed between the surface by capillary action.

Brazing is basically the same a soldering, but it gives a much stronger


joint than soldering. The principal difference is the use of harder filler
material, commercially known as a speller, which fuses at
some temperature above red heat, nut below the melting temperature of
the parts to be joined.

PROCESS:
Brazing joins parts by heating them to more than 840°F and applying a filler
metal that has a melting temperature below that of the base metal. Filler metal
flows into the joint by capillary attraction.

Brazing has several advantages. Dissimilar metals can be joined. Assemblies


can be brazed in a stress-free condition, and complex assemblies can be brazed
in several steps by using filler metals with progressively lower melting
temperatures. Materials of different thicknesses can be joined, as can cast and
wrought metals. Nonmetals can be joined to metals when the nonmetal is
coated. Metallurgical properties of base materials are not seriously disturbed,
and brazed joints require little or no finishing.

Brazing is typically done with a torch or in a furnace. Other methods include


dip, resistance, and induction brazing.

Torch brazing joins relatively small assemblies made from materials that do


not oxidize at the brazing temperature or can be protected from oxidation with
a flux. The most commonly used filler metals include aluminum-silicon alloys,
silver-base alloys, and copper-zinc alloys. Flux is required with these filler
metals unless protective atmosphere is used. Self-fluxing copper-phosphorus
alloys are also used. Torch brazing is done in air and is the most common
brazing process.

Normally, torch brazing is done with handheld oxyfuel gas torches using
various fuels. However, there are automated machines that use preplaced
fluxes as well as preplaced filler metal in paste, wire, or shim form. Torch and
machine brazing are generally used to make lap joints in sections from 0.01 to
0.25 in. thick. Joints can be brazed rapidly, but speed decreases as material
thickness increases.

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”

MANUFACTURING PROCESS:
We will discuss the process of engine block:

The engine block is the metal housing containing the inner workings of an
internal combustion engine. It is of critical importance to the operation of
your engine. If the engine block cracks, your car should not be driven until it
is repaired or replaced.

Material
Engine blocks were traditionally made from cast iron, but in the interest of
better fuel mileage, lighter aluminum alloys have been introduced. The metal
is heated to 800 degrees C and then poured into a sand mold where it
hardens and sets.

Sand Casting
The sand molds used to cast engine metal can be used only once. Zircon
sand, glue and a hardener are mixed and shaped into sections. This is then
solidified with gas. The sections are glued together to form the entire mold
in which the engine block is cast.

Casting and Machining


Once the liquid alloy is poured into the mold and has set, the mold is heated
to break down the glue that solidifies the sand. The sand will then pour off
of and out of the hardened engine block. Tooling equipment machines the
engine blocks before they are inspected and sent to engine assembly plants
where final machining is done before engine assembly.

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