MIG WELDING
Foundry meaning in hindi
जिस स्थान पर काम पिघला हुआ धातु पिघलाने और मोल्ड में डालने से तैयार किया जाता है, उसे फाउंड्री के रूप में जाना जाता है।इस प्रक्रिया में, रेत या किसी धातु द्वारा एक सांचा तैयार किया जाता है।यदि रेत द्वारा तैयार किया जाता है, तो Sand मोल्डिंग के रूप में जाना जाता है मोल्डिंग के लिए उपयोग की जाने वाली रेत है:
- Green sand
- Dry Sand
- Loam Sand
- Facing Sand
- Parting Sand
यह रेत रेत के सामग्री को जोड़ने के लिए तैयार किया जाता है.इसके बाद पैटर्न की मदद से एक सांचा बनाएं। मोल्ड किसी भी वांछित आकार का हो सकता है। पैटर्न फ्लास्क(Flask ) में रखा गया है और उचित घुसाया गया है। मोल्ड पूरा होने के बाद पिघला हुआ पदार्थ(Molten Metal ) गर्मी से तैयार किया जाता है। ठोस पदार्थ को एक Crusible के माध्यम से भट्ठी में रखा जाता है। जब सामग्री तरल हो जाती है तो क्रूसिबल हैंडल की मदद से इसे मोल्ड में डालना होता है। उत्पाद को ठंडा करने के बाद एक piece तैयार किया जाता है। ऊपर वर्णित प्रक्रिया को कास्टिंग कहा जाता है।
Green Sand
मोल्ड green sand की रेत से तैयार किया जाता है और डालने का कार्य रेत में रेत के साथ किया जाता है और इसकी हरी या प्राकृतिक अवस्था को ग्रीन सैंड मोल्डिंग के रूप में जाना जाता है। हरी रेत के उत्पादन के लिए मिश्रण तैयार किया जाता है, जिसमें सिलिका रेत (Silica Sand) होती है। हरी रेत का निम्न अनुपात।
1. Clay 10 से 15%
2. नमी 4 से 6%
Clay और नमी की सामग्री se इसे मिलाया jata hai। पूरा होने के बाद, रेत का मिश्रण फ्लास्क ड्रैग (drag the bottom part of flask)भाग को खोलने के लिए लकड़ी के बोर्ड को फर्श पर रखता है। Flask को लकड़ी के बोर्ड पर रखें। लकड़ी का बोर्ड अनिवार्य नहीं है यह वैकल्पिक है। इसके बाद, पैटर्न को खींचकर रखा जाता है और अगर पैटर्न एकल हो तो सामना करना पड़ता है। यदि पैटर्न को विभाजित किया जाता है, तो पैटर्न के ड्रैग पार्ट को पहले रखें और स्ट्राइक ऑफ बार की मदद से अलग किया गया। रेत ठीक से घुसा हुआ है और बॉक्स पलट गया। पैटर्न का दूसरा भाग स्थिति में रखा जाता है जिसके बाद सामना किया जाता है। रनर और रिज़र को स्थिति में रखा जाता है और बॉक्स को रेत से भर दिया जाता है और ठीक से घुसाया जाता है। रनर पर, इसमें सामग्री डालने के लिए चिकनी डालने के लिए बेसिन डालना। वेंट तार का उपयोग वेंट प्रदान करने के लिए किया जाता है। पैटर्न को हटाने के बाद बक्से को इकट्ठा किया जाता है। सांचे को तैयार किया जाता है।
Dry Sand
यह प्रक्रिया रेत की संरचना की अपेक्षा करने के लिए ग्रीन्सैंड मोल्ड के समान है। रचना हरी रेत से अलग है। सूखी रेत तैयार करने के लिए विशेष प्रकार के बांधने की मशीन का उपयोग किया जाता है जैसे कि राल, मिट्टी या गुड़। इसका उपयोग एक मजबूत बंधन बनाने के लिए किया जाता है। यहां फिर से वही प्रक्रिया दोहराई जाती है। पूरा होने के बाद, सूखी रेत का मिश्रण, ड्रैग रखें और पैटर्न डालें। उसी तरह जब लकड़ी के बोर्ड की आवश्यकता होती है यदि फर्श चिकना नहीं है तो सूअर का उपयोग करें यदि नहीं, तो यह अनिवार्य नहीं है यह वैकल्पिक है। इसके बाद, पैटर्न को ड्रैग और सामना के बीच रखा गया। यदि पैटर्न को विभाजित किया जाता है, तो पैटर्न के ड्रैग पार्ट को पहले रखें और अतिरिक्त सैंड को स्ट्राइक ऑफ बार की मदद से हटा दिया जाता है। रेत ठीक से घुसा हुआ है और बॉक्स पलट गया। पैटर्न का दूसरा भाग स्थिति में रखा जाता है जिसके बाद सामना किया जाता है। रनर और रिज़र को स्थिति में रखा जाता है और बॉक्स को रेत से भर दिया जाता है और ठीक से घुसाया जाता है। यहां एक ही मोल्डिंग बॉक्स को ओवन या स्टोव के साथ टेम्पर्ड किया गया है। गर्मी की मदद से रेत में सभी नमी को हटा दें। सूखी रेत का सांचा तैयार किया जाता है।
Loam Sand
लोम रेत की प्रक्रिया ऊपर वर्णित उन दो से पूरी तरह से अलग है। सबसे पहले, ईंट और दोमट रेत का उपयोग करके हाथ से संरचना तैयार की जाती है। स्टिक और स्वीप के माध्यम से वांछित आकार बनाने के लिए दोमट रेत और ईंटों द्वारा किया जाता है यह एक पैटर्न रहित प्रक्रिया है। पैटर्न के अभाव में भी यही प्रक्रिया की जाती है। मोल्ड के पूरा होने के बाद, इसे ताकत देने के लिए बेक किया जाता है। इसमें मोल्ड बनाने के लिए दोमट रेत और मिट्टी का अतीत तैयार किया जाता है।
Facing Sand
इसे मोटी रेत कहते हैं। Facing रेत का मतलब पैटर्न के चारों ओर इस प्रकार की रेत है। यह fresh और अच्छी तरह से टेम्पर्ड रेत है। रेत का सामना करके दिए गए पैटर्न की सतह के आसपास प्रारंभिक कोटिंग कि जाती
Parting Sand
पार्टिंग सैंड जिसे नाम दिया गया है, इसका उपयोग दो हिस्सों के बीच और सुरक्षित हटाने के लिए पैटर्न के आसपास किया जाता है। दो भागों का मतलब होता है Cope and Drag।जली हुई रेत और सूखी सिलिका रेत का इस्तेमाल जुदाई रेत के रूप में किया जा सकता है।
Hammer
The striking tools are used in different shops for different operations. The striking tool is identified by a hammer. These hammers are used for chipping, fitting and punching process. A hammer has a heavy iron body with wooden handle. The weight range from 0.25 kg to 2 kg. The hammer is many types but the classification of the hammer can be done by their shapes of pean. The pean is the top part of the hammer. When the pean shape changed the name of the hammer also changed.
Straight Pean Hammer
If the shape of pean is parallel to the handle of the hammer is called straight pean hammer.
Ball pean hammer
The shape of pean is like a ball or spherical is called a ball pean hammer.
Cross pean hammer
If the pean across the handle then it is called cross pean hammer. It has cast steel body. This type of hammer is used for wooden work and metallic work.
Double-ended hammer
If the shape of pean is same as face it is called double-ended hammer.
Claw Hammer
The claw hammer is used for striking and pulling the nails from the wooden piece. The one end is made for striking and second claw face. The weight varies from 0.25 kg to 0.75 kg.
Mallet
It is made up of hardwood and round or rectangular in shape. It is used to strike the chisels which are wooden handle.
Hand Hammers
Hand hammer is a light in weight used by Smith himself. Sledgehammer is heavier in weight and is used by the Smiths helper. All the hammers are divided into 4 parts namely
Hand hammer is a light in weight used by Smith himself. Sledgehammer is heavier in weight and is used by the Smiths helper. All the hammers are divided into 4 parts namely
Cold Chisel
This is also a cutting tool which is used on the workpiece as a cold or hot condition. These are made up of high carbon steel. It is generally 6 inches to 8 inches long. The top is flattened and sharp cutting edge made on the bottom side. Chisels are classified on the basis of shape and width of the cutting edge. Commonly used forms of chisel are flat, cross cut, half round and diamond point chisel.
Cutting angle of chisels
For hard material 70-75 degree
For medium hard material 60 degree
For soft material 40 degree
Flat Chisel
This chisel is flat in shape at the end side. The flat chisel is used for chipping a large surface. This chisel is used at room temperature so it is called as a cold chisel.
Crosscut chisel
The crosscut chisel is narrow chisel and thickness of the cutting edge is broader than a flat chisel. The flat chisel is used for cutting grooves.
Half round chisel
The half round chisel is used to cut oil grooves in the bushes and also clearing small round corners.
Diamond point chisel
The diamond point chisel is used for chipping plate. It is also used for clearing the corner of the slots cut at an angle or of a square shape.
Chipping with chisel
The workpiece is proper to hold in the vice. The material is removed with the help of a hammer. The chisel has held an angle to the workpiece. The chisel is perfectly held in the hand while striking.
Flat file
Files
A file is a tool which has multi-tooth. It is used for remove the unwanted material by means the rubbing on the metal. The files are available in many shapes and size.
- Rough
- Bastard file
- Second cut
- Smoothe
- Dead smooth
The rough file and bastard file are the big cut files. Where material is more the rough file is used. These files have bigger teeth.
Dead smooth file smooth have smaller teeth and used for finishing work. The second cut file has the degree of finish midway between bastard and smooth file.
Classification on the basis of shape and size
The files are available in many shapes and size. The length of the file varies from 4 inches to 14 inches. The shapes available are square, round, triangular, half round, etc.
Number of cuts
According to the cuts, the file are two types
Single cut
In the single cut file, the teeth of the file are cut in parallel rows at 60 degrees to the face.
Double cut
In the double cut file, the teeth of the file are cut in parallel rows and the opposite direction at 60-degree angle.
Pitch
The number of teeth in one centimeter is called pitch of the file. The number of teeth varies from 10 to 40 in one centimeter.
Use of file
The file is held in perfect and horizontal in position. Most of the files have their teeth pointing forward. So the pressure should be applied in forward stroke. The work is held in a vice after marking. Keep the right hand on the handle and left hand of the left end. The file movement (Forward and backward )speed of 15 to 25 stroke per minute. The rough file is used where material removing is the more and fine file is for finishing work.
Care of file
- The teeth should be protected from excessive wearing.
- The file should be stored in wooden rake.
- Clean the file after use by the file cleaner.
- The file should be coated with oil when not in use.
Hand Hacksaw frame
Cutting tools
The tools which are used to remove or cut the material is known is cutting tools.
Hand Hacksaw
Hand Hacksaw is used for cutting of rods, flat, etc. The Blade of the hacksaw is made up of high Carbon Steel or high-speed steel. And the frame is made from mild steel. The Blade is placed inside the frame and tightened with the help of flange nut. The teeth of the blade are generally forward cut. The hacksaw should be used in a straight direction otherwise it will result in breaking of blades. The length of blades varies from 8” to 14” but generally in 12 inches blade is used in a fixed hacksaw frame.The thickness and width of the blade are 1 mm and 1/2 inches respectively.
Classification of blades
According to the direction of cut
Forward cut Backward cut
Depending upon the pitch of the teeth
Coarse
Medium
Fine
Type of hacksaw frame
There are two types of hacksaw frame
Fixed hacksaw frame
In fixed hacksaw frame only one type of blade is used.
Adjustable frame
In the adjustable frame, the teeth of the frame can be increased or decrease as per requirement and the blade from 8 inches to 14 long can be used in it.
Pitch of hacksaw
It is the number of teeth on the blade in one centimeter. Hacksaw blade with small pitch is used for the thin section and the large pitch are used for the thick section.
Use of the Hacksaw
The material to be cut with a hacksaw is clamped into vice. Marking is done with the help of a scribe. The hacksaw handle is held in right hand and the frame is kept on left hand. Start sawing at the marking, keeping the blades slightly inclined to the horizontal. The direction of hacksaw should be straight and horizontal. The speed of the hexa should be 15-25 stock per minute. Sufficient pressure should be given to the frame with the left hand while in forwarding stock. Water can be used as a coolant for sawing.
Care of hacksaw
- Always move the hexa in the perfectly straight and horizontal direction.
- Never tilt the frame while sawing.
- While cutting thin section wooden piece must be clamped along with the workpieces.
- Never use a new blade where the cut is already made by another blade.
- The blade should be tightened sufficiently.
Gas welding
The gas flame is used to raise the temperature and produce heat with the help of gases. The metal is heated up to melting the metal and on cooling it solidify. Filler metal is used for fill the gap of welding and preparation the edges of joints. Many combinations of gases are used in gas welding but commonly used is Oxygen and acetylene.Oxy-Acetylene welding
The process of oxy-acetylene welding can be used for all .types of metal which is used for engineering purpose. Oxy-Acetylene welding can produce 3200-degree Celsius. These are two systems of oxygen acetylene welding
High pressure system
In this process, the oxygen and acetlyene are taken for use from a high pressure cylinder.
Low pressure system
In this system, oxygen is filled in a high-pressure cylinder and the acetylene is produced by the addition of calcium carbide and water.
CaC2 + 2 H2 O = Ca (OH)2 + C2 H2
Principle of Oxy-acetlyene welding
When the gases began burning the flame is produced through the torch tip. The edge to be welded are heated upto melting. Filler metal is also added to complete the welding. This molten metal mixture when soldify on cooling forms a welding joint.
Apparatus
Oxygen cylinder
Acetylene cylinder
Pressure gauges
Valve
Hosepipe
Torch
Welding tips
Pressure regulators
Lighter Goggles.
The cylinder filled with oxygen and acetylene. Both the cylinders are attached with pressure gauge, regulator and cylinder valves. The cylinder containing oxygen is painted black where the acetylene cylinder is painted Maroon. Hose pipe are provided with each cylinder. These pipes are connected to the welding torch.
Welding process
To start welding the acetylene control valve is turned first when acetylene comes out of the nozzles it should be ignited with the spark lighter. It will give a yellow coloured smoke flame after it oxygen cylinder valve is opened and supplied is increased until the best suitable flame is obtained. Then the flame is foucussed on the edges to be welded flux and filler matel are also added with the help of heat of frame, the edges and filler metal metals and a joint is performed after cooling of the molten metals. The joint may be formed with or without using filler metals.
Applications
Same equipment may be used for cutting purpose . Oxy-acetylene welding is particular is used for sheet metal works.
Types of gas flames
Oxidising flame
When the volume of oxygen is more than the volume of the acetlyene mixer into the torch. This types of flame are used for cutting the metal and welding the brass metal.
Carburising flames
When the volume of acetylene mixed in more than oxygen carburizing frame is formed. This flame is used to welding nickel, monel
Neutral flame
It is known as balancing flame oxygen and acetylene gases are mixed in equal volume. This types of flame used for welding steel and cast iron.
Flux
The chemical which deoxidise the metal surface and provide an inert atmosphere around the molten metal is known as flux. The function of flux
- To prevent oxide from the hot surfaces
- To reduce the viscosity of molten metals
- It contains a study Arc in the case of arc welding.
Flux is available in liquid, powder, paste, and gas. Powder flux is sprinkling on the surface to be welded or the filler rod is dipped into the Powder liquid and paste flux are sprayed on the surface to be welded. Gas fluxes are used to form in the inert atmosphere around the joint to be welded.
Filler metal
The rod which provide additional metal in completing the welding is known as filler metal. The composition of filler metal should be same as metals to be welded
Fitting Shop Tools
Fitting Shop Tools
Clamping tools
The clamping tools that are used in the fitting shop are called vices and this is used for holding the jobs firmly during various is fitting operations.
Bench vice
For holding the jobs bench vice is used. It has cast iron body. Two jaws plates are fitted on both the Jaws. Jaws plates are made up of high carbon steel and are wear resistant. One jaw is fixed to the body and the second slide on the square threaded screw with the help of handle. The jaws are open up to required length, the job is placed in the two jaws and is fully tightened with handle. It is fixed at the four corners of the fitter ’s working Bench and it is up to the waist height.
Leg Vice
It is made of mild steel and the jaws are of cast Steel. It is stronger than parallel jaws bench vice and used for heavy works. It is used when the operation such as chipping or hammering is to be performed. It is fixed on the bench grouted in the foundation.
Hand vice
The small objects are held in the hand vice. These are made of different shapes and size. It has two steel legs which joined at the bottom. A Spring is provided between two legs. The jaws are holding with nuts.
Pin vice
For holding small diameter rods and wire are used to pin vice. It is also used for grinding small drills. It consists of small chucks made up of tools steel and mild steel handle.
Pipe vice
It is used to hold pipes. A movable joint fixed on the lower end of the screw. It grips the pipe at four points. The Jaws of this pipe vice are V-shaped. This vice can be fixed on the bench or it can be grauted.
Measuring and marking tools
Try Square
It is used for checking the squareness of two surfaces. It consists of a blade made up of Steel which is attached to a base at 90 degrees. Try square is also used for marking right angle and measuring straightness of surface. It is an instrument used to draw a straight line at right angle to a true surface.
Bevel protector
It consists of a steel dial divides into the 360-degree division. The dial can be rotated around the center the lines at any angle can be marked on or measured by the straight edge. The straight edge can be slide along the length.
Combination set
It is a multipurpose instrument that can be used as a protector, a level, a miter, a center square, and a try square.
Centre Square
Center square is used to find the center of the round jobs. It consists of straight edge and two arms for finding out the center in around the job is placed between two arms.
Scriber and Surface Gauge
It is used for marking of lines. Scriber mount on a vertical bar is called surface gauge. A heavy base is provided at the bottom. There is not fixed on the bar and this nut the scriber can be loosened and fixed anywhere in the bar in this way the inclination can be varied. It is kept on the surface plate during any measurement Primarily it is used along with V block to draw a line parallel to the surface.
Universal marking surface gauge
Dot punch
It is used for marking dotted lines. Its material is high carbon or high-speed steel. One end is sharpened and the second end is flat and hammering is done on this end while working. The angle of the punch end is 60 degree.
Center punch
It is like a dot punch expect the angle of punching end is 90°.
Surface Plate
Angle plate
It consists of cast iron in which two ribs of metals are standing at a right angle to each other. Holes are providing for clamping purpose. It is used for holding and Sporting the jobs.V block
Steel rule
These are made up of stainless steel and are available in many sizes ranging from ½ ft to 2ft. These are marked in inches and millimeter. The edges of the steel rule should be protected from rough handling.Cutting Tools
The tools which are used to remove or cut the material is known is cutting tools.
Learn also: Fitting Shop Tools in Hindi
Learn also: Fitting Shop Tools in Hindi
Hand Hacksaw
Hand Hacksaw is used for cutting of rods, flat, etc. The Blade of the hacksaw is made up of high Carbon Steel or high-speed steel. And the frame is made from mild steel.
Files
A file is a tool which has multi-tooth. It is used for remove the unwanted material by means the rubbing on the metal. The files are available in many shapes and size.Striking Tools
Hammer
The striking tools are used in different shops for different operations. The striking tool is identified by a hammer. These hammers are used for chipping, fitting and punching process. A hammer has a heavy iron body with wooden handle. The weight range from 0.25 kg to 2 kg.
Forging Tools Name
Forging tools name with the images
Anvil
Anvil is the sporting device which is a sport the material when hammering is performed on it. A block on which forging work is done is called Anvil. It is made up of Steel, cast iron or wrought iron. It acts as a Sporting device for all forging operation. The weight of the anvil varies from 100 kg to 150 kg. It is available in many size and shape
Hammer
Hammer is used as a striking tool. It is divided into three types. Hand hammer
Sledgehammer
Power hammer
Hand hammer is a light in weight used by Smith himself. Sledgehammer is heavier in weight and is used by the Smiths helper. All the hammers are divided into 4 parts namely.
1. Pean 2. Eye 3. Cheeks 4. Face.
Hand hammer of four types based on the shape of pean if the pean is along the axis of the handle then it is straight peen hammer. When the pean is across the axis of the handle then it is called cross pean hammer. In case the shape of the pean in same as the shape of the face then it is double ended. If the shape of the pean is spherical then it is a ball peen hammer. The weight of hand hammer vary from 1 kg to 2 kg and that of the sledgehammer is 3 kg to 8 kg. When the quantity of jobs is to be produced is more the power hammer is used. Commonly used Hammer:-
Spring hammer
Pneumatic hammer
Steam hammer
Drop hammer
The power hammer is generally driven by electrical power. The job to be produced is placed on the anvil of the hammer with the help of the liver the weight is allowed to fall on the job. The factor which influences the working of the hammer.Size and shape of jobs
The falling weight of the hammer
The height of the falling weight
Tongs
Tongs are used for holding and turning hot metal pieces depending upon their uses, tongs are classified into many types. All types of tongs have a similar construction to accept the mouth. Tongs have two legs shifted from a suitable place these are made up of mild steel. Various types of tong used in forging shop it is made in two pieces and both of the pieces are joined by hinges. The length of the tong varies from 12" to 18".It is classified based on the shape of the mouth of the tongs.Chisel
Chisel is used for cutting a metal piece in hot and cold states. Chisel is divided following categories.
Hot chisel
Cold chisel
Hard die set
Hot chisel is used to cut the metal in a hot state and cold chisel to used cut the metal in cold state, the main difference between these chisels is the cutting angle. In hot chisel, the cutting angle is 30 degree but in the case of a cold chisel, it is value is 60 degree. Hard die set. A hard die set consists of three parts:-
1.Shank 2. Body 3.Cutting Edges
The shank is fitted into the hard die hole in the anvil. Chisels and the hard reset are made from carbon steel. It is hardened up to the desired label with proper tampering.
Punches and drifts
Punches are made up of high carbon steel and are used for making of a rough hole in hot metal pieces. Punches are available in different size but have a common shape. A drift is a largely sized punch used to enlarge a whole.
Flatter
Flatter, as indicated by the name flatter, is used to flattening the workpiece. It is held in a thin wire. The material of the flatter is high Carbon Steel. The body of the flatter is squared in cross-section.
Fuller
Fuller is used for grooving and drawing. These are made in two-piece lower and upper parts. The lower part is mounted on the Anvil and the upper part is held in hand from a wire handle. These are made up of high carbon steel and medium carbon steel. These are used for hot work only.
Swages
Swages are used for giving various shape to the workpieces. These are made up of high carbon steel and used in two pieces as in case of fuller.
Swage Block
Swage block it is a cast iron or cast steel rectangular block having a number of holes on it. Holes are made in different size and shapes. Its outer sides are also made sectional forms to receive various types of jobs. It is always planning on the cast iron frame.
Set Hammer
Set hammer have a similar shape to the flatters. It is made to tool steel.
Clamping vice
Clamping vice is only clamping device used in Smithy shop. It is mounted with a table or wooden base. It consists of two jaws a spring,and a leg.The hot workpiece is clamp in it while working.
Pattern Allowance in Casting
Pattern shrinkage allowance
After the pouring the molten metal into the mold, the metal has a tendency to contract during solidification. The total casting product has shrunk and become small than the pattern. The difference occurs between the pattern and casting is known as shrinkage allowance. The factor that affects the shrinkage is temperature while pouring the metal, the material of the mold and method of molding.
Machining allowance for sand casting
Matching allowance may be required by casting may partially or fully. In drawing the portion to be machined to be identified and in those portion machine allowance is provided apart from shrinkage allowance. Machining allowance also depends upon casting metal, machining methods, the specification of casting and the finish required.
Draft allowance in casting
In the draft allowance, the pattern remains taper from all vertical surfaces. It provides the internal and external surfaces. It is required for easy removal of the pattern. It depends upon the vertical height and molding method.
Shake allowance in a pattern
Before withdrawal of the pattern fist of all, it is shaken so that it is free from the adjoining wall, due to this size of mold cavity increase so a negative allowance is given to the pattern.
Distortion allowance in casting
There are certain casting in which the cooling of the metal is not uniform throughout the casting due to very complicated shape. Due to this distortion in the casting.
Movement of the mold wall
Due to excessive heat, the wall of the mold has a tendency to move, this movement of the wall affects the final size in the casting.
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