1. Subject Name: MANUFACTURING PROCESS Subject Code: 10AE35
Prepared By: RAVISHANKAR. M & RADHAKRISHNAN.P
Department: AERONAUTICAL ENGINEERING
Date 05/11/2014
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2. Topic details
Single point cutting tool nomenclature, geometry of single point cutting tool.
Merchant’s circle diagram and analysis.
Ernst-Merchant’s solution, Shear angle relationship.
Tool wear and tool failure, tool life, effects of cutting parameters on tool life.
Tool’s failure criteria, Taylor’s tool life equation.
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3. Soldering and brazing is essentially a welding process done at lower temperature where the base metal or work piece doesn’t undergo melting and soldification.
If the joining process done above 450 degree Celsius but below 650 degree Celsius it is brazing.
If the temperature is less than 450 degree Celsius it is referred to as soldering.
TYPES OF BRAZING
Torch brazing
Furnace brazing
Induction brazing
Resistance brazing
Dip brazing
Salt bath brazing
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4. TORCH BRAZING
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5. FURNACE BRAZING (CONVEYOR TYPE)
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6. TYPES OF SOLDERING JOINTS
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7. WETTABILITY PRINCIPLE
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10. Gas torch equipment
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11. The flame produced in combustion of oxygen and acetylene is about 3200 degree Celsius.
Different applications require different flame which can be obtained by regulating the gas flow
Three types of flames can be produced.
NEUTRAL FLAME [OXYGEN:ACETYLENE :: 1:1]
The gases are in equal proportions.
Temperature is about 3260 degree Celsius.
Flame light blue in colour.
Blue flame is surrounded by outer flame produced by combination of oxygen and carbon monoxide, hydrogen in the inner zone.
This flame type does not produce any chemical change in molten metal.
Used for welding mild steel, cast iron, aluminium, copper and stainless steel.
OXIDIZING FLAME [OXYGEN:ACETYLENE :: 1.5:1]
After establishing neutral flame, the oxygen content is increased.
The resulting flame is oxidizing in nature.
Flame small short cone, dark blue in colour and more pointed than in the neutral flame.
Outer envelope much shorter than the first.
Temperature is about 3840 degree Celcius.
Excess oxygen tends to combine with metals to form hard, brittle low strength oxides.
Limited use in welding.
Slightly oxidizing flame is used in welding copper base alloys, zinc base alloys.
Wherein preferential oxidation of one of the elements provides a protective layer.
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12. REDUCING FLAME [OXYGEN:ACETYLENE :: 1:1.5]
After neutral flame establishment, acetylene gas amount is increased.
The resulting flame is reducing in nature.
Outer flame envelope is longer than that of neutral flame and is usually much brighter.
A reducing flame does not completely consume the available carbon.
Therefore the temperature is lower and unconsumed carbon is forced into the molten metal.
A reducing flame ensures the absence of oxidation, metals that absorbs carbon should not be welded with this flame.
Non ferrous metals, high carbon steels can be welded with this flame.
A carburizing flame contains excess acetylene than a reducing flame.
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14. Applications
Joining thin sections
Most of ferrous and non ferrous metals can be gas welded.
Automobile and aircraft industries in sheet metal joining.
Types of welding
Gas welding can be carried out in two ways namely,
Leftward/Forward welding
Rightward/Backward welding
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15. ARC WELDING
Electric arc is used as the heat source
An electric arc is a continuous stream of electrons flowing between two electrodes into a medium.
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16. ARC WELDING PARAMETERS
Arc current
Arc length
Electrode diameter
Shielding gases
Welding time
CLASSIFICATION OF ARC WELDING
Flux welded arc welding
TIG/MIG welding
Submerged arc welding
Resistance welding
Special welding methods
Laser welding
Atomic Hydrogen welding
Plasma welding
Thermit welding
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19. SUBMERGED WELDING
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