Workshop Processes and Materials I

Frontmatter

Part One

Frontmatter

Introduction

Abstract

The object of this first part is to provide the student with a relatively brief summary of the work required in the safety and materials sections of the Standard Unit. Plastics are also covered, including joining and forming techniques.

P. J. Avard, J. Cross

Section 1. Safety at Work

Abstract

Being aware of the hazards present in an engineering workshop is the first step towards avoiding them.

P. J. Avard, J. Cross

Section 2. Materials

Abstract

Materials used in the engineering industry can be divided into three categories: (1) ferrous metals, (2) non-ferrous metals and (3) non-metallic materials.

P. J. Avard, J. Cross

Part Two

Frontmatter

Introduction to Process Notes

Abstract

The intention of this work is to bring the student into contact with the tools, instruments, materials and machines as soon as possible, so as to make the ensuing lectures more meaningful.

P. J. Avard, J. Cross

Process 1. Centre lathe, turning between centres. (Figure 1.1)

Abstract

To observe and note the construction of the tailstock and provisions made for ‘across the bed’ adjustment, to produce parallel and tapered work between centres.

P. J. Avard, J. Cross

Process 2. Centre lathe turning, four jaw chuck

Abstract

To produce a concentric round spigot on the end of a square bar. (Figure 2.1)

P. J. Avard, J. Cross

Process 3. Taper turning (compound slide)

Abstract

To machine matching external and internal tapers. (Figure 3.1)

P. J. Avard, J. Cross

Process 4. Screw cutting (single-point tool)

Abstract

To produce a machined screw thread (figure 4.1) by setting compound slide half thread flank angle; observing important features of the screw thread, and noting the principles of forming and generating.

P. J. Avard, J. Cross

Process 5. Turning eccentrics. (Figure 5.1)

Abstract

To study methods of offsetting work to produce eccentrics, either to open tolerances or close limits.

P. J. Avard, J. Cross

Process 6. Centre lathe, taper-turning attachment

Abstract

To machine a number 3 Morse taper (figure 6.1) and to observe the advantages and disadvantages of the method.

P. J. Avard, J. Cross

Process 7. Centre lathe, face plate

Abstract

Boring an accurately positioned hole in a bearing block, set on an angle bracket mounted on a face plate.

P. J. Avard, J. Cross

Process 8. Shaping a vee-groove

Abstract

To observe (1) the relative positions of the machine front slide and clapper box, and (2) the method used to obtain accurate depth and position.

P. J. Avard, J. Cross

Process 9. Shaping

Abstract

To examine the problems of machining dovetail slides and the function of the clapper box, particularly on the 60° inverse face. Also to test a method of accurate measurement of the slide contact faces.

P. J. Avard, J. Cross

Process 10. Marking-out, hand sawıng and filing

Abstract

To show the potential of hand skills.

P. J. Avard, J. Cross

Process 11. Marking-out

Abstract

To check the degree of accuracy obtainable by marking-out with a vernier height gauge, and to position the locations of machining areas, thus saving setting and machine loading times.

P. J. Avard, J. Cross

Process 12. Spacing holes on a pitch circle

Abstract

To show the potential of hand skills: power hand drilling, marking-out.

P. J. Avard, J. Cross

Process 13. Marking-out, drilling and reaming

Abstract

To show the potential of hand skills: spacing holes accurately, obtaining a good finish and close dimensioning of hole diameter.

P. J. Avard, J. Cross

Process 14. Marking-out, heat treatment, drilling and bending

Abstract

To examine the mechanical properties of mild steel; the application of powered hand tools.

P. J. Avard, J. Cross

Process 15. Accurate hole spacing

Abstract

To study the function and capability of a compound table fitted to a standard drilling machine for jig boring.

P. J. Avard, J. Cross

Process 16. Soft soldering

Abstract

To study the nature of a soft soldered joint and other forms of soldering.

P. J. Avard, J. Cross

Process 17. Milling—producing a concentric square on a round bar. (Figure 17.1)

Abstract

To detail a method of ensuring positive concentricity of the square to the round bar.

P. J. Avard, J. Cross

Process 18. Milling—angular indexing

Abstract

Using the 40:1 dividing head for angular indexing to mill a vee-slot, for marking two lines angled to each other as shown in figure 18.3, and for converting the angle to the dividing head spindle rotation (figure 18.8).

P. J. Avard, J. Cross

Process 19. Milling a four-jaw coupling (or jaw clutch). (Figure 19.1)

Abstract

To study the problems of work positioning, indexing the dividing head, and providing a working clearance between the mating faces of a similar coupling.

P. J. Avard, J. Cross