Engineering Fundamentals

Front Cover......Page 1
Engineering Fundamentals......Page 4
Copyright Page......Page 5
Contents......Page 6
Preface......Page 12
Acknowledgements......Page 13
1.1 Health, safety and the law......Page 14
1.2 Employers’ responsibilities......Page 16
1.3 Employees’ responsibilities......Page 18
1.4 Electrical hazards......Page 19
1.5 Fire fighting......Page 20
1.6 Fire precautions and prevention......Page 23
1.7 Accidents......Page 24
1.8 First aid......Page 27
1.9 Personal protection......Page 29
1.10 Hazards in the workplace......Page 33
1.11 Manual lifting......Page 38
1.13 Use of lifting equipment......Page 40
1.14 Accessories for lifting gear......Page 41
1.15 Useful knots for fibre ropes......Page 44
1.16 Transporting loads (trucks)......Page 45
1.17 Inspection (lifting equipment)......Page 46
Exercises......Page 47
2.1 Basic relationships......Page 51
2.2 Relationships with managers, supervisors and instructors......Page 53
2.3 Attitude and behaviour......Page 55
2.4 Implementing company policy......Page 56
2.5 Creating and maintaining effective working relationships with other people......Page 59
Exercises......Page 60
3.1 Selection of information sources......Page 63
3.2 Interpretation of information (graphical)......Page 64
3.3 Interpretation of information (tables, charts and schedules)......Page 67
3.4 Evaluating engineering information......Page 70
3.5 Recording and processing engineering information......Page 71
3.6 Methods of record keeping......Page 72
3.7 Communications (miscellaneous)......Page 73
Exercises......Page 76
4.1 States of matter......Page 78
4.2 Properties of materials......Page 79
4.4 Ferrous metals (plain carbon steels)......Page 86
4.5 Ferrous metals (alloy steels)......Page 89
4.7 Abbreviations......Page 92
4.8 British standards for wrought steels......Page 93
4.9 Non-ferrous metals and alloys......Page 94
4.11 Non-metals (natural)......Page 100
4.12 Non-metals (synthetic)......Page 102
4.13 Forms of supply......Page 105
4.15 Heat treatment processes (safety)......Page 107
4.16 The heat treatment of plain carbon steels......Page 110
4.17 The heat treatment of non-ferrous metals and alloys......Page 122
4.18 Heat treatment furnaces......Page 123
4.19 Temperature measurement......Page 128
4.20 Atmosphere control......Page 131
Exercises......Page 132
5.1 Engineering drawing (introduction)......Page 136
5.2 First angle orthographic drawing......Page 137
5.3 Third angle orthographic drawing......Page 140
5.4 Conventions......Page 142
5.5 Redundant views......Page 146
5.6 Dimensioning......Page 147
5.7 Toleranced dimensions......Page 150
5.8 Sectioning......Page 151
5.9 Machining symbols......Page 153
5.10 Types of engineering drawings......Page 154
5.11 Pictorial views......Page 157
5.12 Sketching......Page 160
Exercises......Page 163
6.2 Linear measurement......Page 168
6.3 Measuring angles......Page 183
6.4 Miscellaneous measurements......Page 188
6.5 Limits and fits......Page 190
6.6 Classes of fit......Page 192
6.7 Accuracy......Page 193
6.8 Terminology of measurement......Page 196
Exercises......Page 197
Answers......Page 199
7.1 Marking-out equipment (tools for making lines)......Page 201
7.2 Marking-out equipment (tools for providing guidance)......Page 207
7.3 Marking-out equipment (tools for providing support)......Page 209
7.4 The purposes, advantages and disadvantages of manual marking out......Page 213
7.5 Types of datum......Page 214
7.6 Techniques for marking out......Page 216
Exercises......Page 228
8.1 Relative merits and disadvantages of using hand tools......Page 231
8.2 The fitter’s bench......Page 232
8.3 The metal cutting wedge......Page 233
8.4 The angles of a wedge-shaped cutting tool and their terminology......Page 234
8.5 The application of the basic cutting angles to hand tools......Page 236
8.6 Chipping......Page 237
8.7 Hammers......Page 239
8.8 Filing......Page 240
8.9 The hacksaw......Page 244
8.10 Screw thread applications......Page 246
8.11 Cutting internal screw threads (use of taps)......Page 249
8.12 Cutting external screw threads (use of dies)......Page 252
8.13 Hand reamers and reaming......Page 254
8.14 Tools used in assembly and dismantling......Page 255
8.15 Preparation of hand tools......Page 261
8.16 Making a link......Page 262
8.17 Checking the link......Page 265
Exercises......Page 266
9.1 The twist drill......Page 270
9.2 Twist drill cutting angles......Page 272
9.3 Twist drill cutting speeds and feeds......Page 273
9.4 Twist drill failures and faults......Page 276
9.5 Blind hole drilling......Page 278
9.6 Reamers and reaming......Page 279
9.7 Miscellaneous operations......Page 281
9.8 Toolholding......Page 283
9.9 Workholding......Page 285
9.10 The basic alignments of drilling machines......Page 288
9.11 The bench (sensitive) drilling machine......Page 289
9.12 The pillar drilling machine......Page 290
Exercises......Page 291
10.1 The safe use of machine tools......Page 294
10.2 Constructional features of the centre lathe......Page 298
10.3 Main movements and alignments......Page 302
10.4 Types of spindle nose......Page 305
10.5 Starting up and closing down the machine......Page 307
10.6 Workholding devices (centres)......Page 308
10.7 Workholding devices (taper mandrel)......Page 311
10.8 Workholding devices (self-centring chuck)......Page 313
10.9 Workholding devices (collets)......Page 315
10.10 Workholding devices (four-jaw, independent chuck)......Page 316
10.11 Workholding devices (faceplate)......Page 319
10.12 Use of steadies......Page 320
10.14 Concentricity......Page 322
10.15 Taper turning......Page 323
10.16 Hole production......Page 325
10.17 Parting off......Page 328
10.18 Cutting screw threads......Page 329
10.20 Chip formation and the geometry of lathe tools......Page 331
10.21 Cutting lubricants and coolants......Page 335
10.22 Tool height......Page 336
10.23 Relationship between depth of cut and feed rates as applied to turning operations......Page 338
10.24 Cutting speeds as applied to turning operations......Page 341
10.25 The production of some typical turned components......Page 343
Exercises......Page 348
11.1 Safety......Page 355
11.2 The milling process......Page 356
11.3 The horizontal spindle milling machine......Page 359
11.4 The vertical spindle milling machine......Page 360
11.5 Types of milling cutters and their applications......Page 363
11.6 Cutter mounting (horizontal milling machine)......Page 365
11.7 Cutter mounting (vertical milling machine)......Page 368
11.8 Workholding......Page 370
11.9 Cutting speeds and feeds......Page 375
11.10 Squaring up a blank on a horizontal milling machine......Page 378
11.11 Milling a step (horizontal milling machine)......Page 380
11.13 Milling a slot (horizontal milling machine)......Page 381
11.14 Milling an angular surface......Page 382
Exercises......Page 384
12.1 Safety when grinding......Page 389
12.2 Fundamental principles of grinding......Page 392
12.3 Grinding wheel specification......Page 393
12.4 Grinding wheel selection......Page 397
12.5 Grinding wheel defects......Page 398
12.6 Grinding wheel dressing and truing......Page 399
12.7 Grinding wheel balancing......Page 400
12.8 The double-ended off-hand grinding machine......Page 402
12.9 Resharpening hand tools and single point cutting tools......Page 405
12.10 Surface grinding machine......Page 406
12.11 Workholding......Page 408
12.12 Mounting a magnetic chuck on the worktable......Page 411
12.13 Grinding a flat surface......Page 413
Exercises......Page 415
Index......Page 418