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Process , advantages and Disadvantages</span></a><div class="copy-container"><header><p><a style="color: #ff392e!important" href="//www.gunkrazy.com/press-forging-process-advantages-and-disadvantages/">Press Forging &#8211; Process , advantages and Disadvantages</a></p></header><div class="excerpt"><p>Press Forging - Process , advantages and Disadvantages
Introduction to Press Forging
Press forging may be defined as the process of shaping a metal that is placed between two dies by applying...</p><div class="button-container"><a rel="nofollow" class="button reverse" href="//www.gunkrazy.com/press-forging-process-advantages-and-disadvantages/" aria-label="View Post: Press Forging &#8211; Process , advantages and Disadvantages">View Post</a></div></div></div></article> <script type="application/ld+json">{"@context":"http:\/\/schema.org\/","@type":"BlogPosting","name":"Press Forging &#8211; Process , advantages and Disadvantages","url":"\/\/www.gunkrazy.com\/press-forging-process-advantages-and-disadvantages\/","articleBody":"Press Forging - Process , advantages and Disadvantages\r\nIntroduction to Press Forging\r\nPress forging may be defined as the process of shaping a metal that is placed between two dies by applying mechanical or hydraulic pressure. Press forging is usually done on a forge press - a machine that applies gradual pressure on the forging dies. The shape of the metal is usually accomplished by a single stroke of the press for each die station.\r\n\r\nThe key difference between impact forging and press forging is that in the former method a sudden impact force is applied on the die, while in the latter method a gradually increasing pressure is applied on the die.\r\n\r\nPress forging may be undertaken as a hot or cold forging process. Press forging is suitable for high volume productivity of forgings. The various forging operations in a press forge and its applications are described below.\r\n\r\nRead More:\u00a0What is Forging and Its types ,Advantages\r\n\r\nThe press forging is similar to drop forging but uses a single, continuous, slow squeezing action instead of a series of impact blows. Because of slow ram travel and continuous action of the hydraulic presses, the deformation penetrates deeper so that the entire volume of the work piece simultaneously and uniformly undergoes plastic deformation. While in case of drop forging, the energy is only transmitted into the surface layers of the work part.\r\n\r\nA good industrial practice is to use shaped blanks or preforms so that it can be forged in a single continuous stroke. The press forging may be of flash type of fleshless. In flash-press-forging, the surplus metal is flashed out in the gutter, provided at the parting line, while in flashless-press-forging, the entire material is utilized to fill the die cavity.\r\n\r\nhydraulic press forging\r\n\r\nTechnique of Press Forging\r\nPress forging is a technique that applies gradual pressure on a die holding a work piece. This can be done as an open die or closed die forging process. In an open die press forging process, the metal is surrounded by the die on one side only. In the case of impression die or closed die forging methods, the metal work piece is enclosed in a die and pressure is applied on the die. Plastic deformation of the work piece occurs and it fills the die cavities.\r\nTypes of Forging Presses\r\nThe three main types of forging presses used for press forging are listed below:\r\n\r\n \tMechanical Press \u2013 converts the rotation of the motor into linear motion of the ram.\r\n \tHydraulic Press \u2013 hydraulic motion of the piston moves the ram.\r\n \tScrew press \u2013 screw mechanism actuates the ram movement.\r\n\r\nAdvantages of Press Forging:\r\n1. Higher productivity than drop forging.\r\n\r\n2. Greater accuracy in terms of tolerances within 0.01 to 0.02 inch.\r\n\r\n3. Dies used in press forging have less draft, therefore more complicated shapes can be forged with better dimensional accuracy.\r\n\r\n4. The speed, pressure and travel of the die are automatically controlled, in press forging.\r\n\r\n5. Possibility of process automation through mechanism of blank feeding and forging removal.\r\n\r\n6. The operation is completed in a single squeezing action, saves the time.\r\n\r\n7. The plastic deformation goes deep into the centre of the work piece, provides uniform and simultaneous deformation throughout the metal.\r\n\r\n8. The capacity of presses ranging from 500 to 9000 tons and the number of working strokes per minute can be high as 40 or even 50. Means 40 to 50 parts produced per minute.\r\n\r\n9. The press forging, therefore, is suitable for mass production of nuts, bolts, rivets, screws, break levers, bearing races, valves, etc.\r\n\r\nLimitations of Press Forging:\r\n\r\nNevertheless, the press forging has certain limitations, these are:\r\n\r\n1. The initial capital cost is higher compared with drop forging, because the cost of crank press is always higher than that of an equivalent hammer.\r\n\r\n2. The difficulty of descaling the blank is another short coming of this process.\r\n\r\n3. The process is economically suitable only when the equipment is efficiently utilized.","headline":"Press Forging &#8211; Process , advantages and Disadvantages","author":{"@type":"Person","name":"Sachin Thorat","url":"\/\/www.gunkrazy.com\/"},"datePublished":"2018-06-07","mainEntityOfPage":"False","dateModified":"February 23, 2020","image":{"@type":"ImageObject","url":"\/\/www.gunkrazy.com\/wp-content\/uploads\/2018\/05\/hydraulic-press-forging-170x300.jpg","height":300,"width":170},"publisher":{"@context":"http:\/\/schema.org\/","@type":"Organization","name":"Learn Mechanical Engineering","logo":{"@type":"ImageObject","url":"\/\/www.gunkrazy.com\/wp-content\/uploads\/2020\/01\/learn-mech-logo-1-300x300.png","height":600,"width":60}}}</script> <article class="article-card horizontal "> <a href="//www.gunkrazy.com/career-in-aviation-maintenance-jobs-salary-duties/" rel="nofollow"><div class="image-container" style="background-image: url('//www.gunkrazy.com/wp-content/uploads/2018/06/What-is-Aircraft-Maintenance-Engineering--300x227.jpg')"></div><span class="sr-only">link to Career In Aviation Maintenance &#8211;  jobs , salary, duties</span></a><div class="copy-container"><header><p><a style="color: #ff392e!important" href="//www.gunkrazy.com/career-in-aviation-maintenance-jobs-salary-duties/">Career In Aviation Maintenance &#8211;  jobs , salary, duties</a></p></header><div class="excerpt"><p>Career In Aviation Maintenance - jobs , salary, duties
The field of aviation maintenance is changing almost as fast as the evolution of airplane and flight maintenance technology. There is a lot to...</p><div class="button-container"><a rel="nofollow" class="button reverse" href="//www.gunkrazy.com/career-in-aviation-maintenance-jobs-salary-duties/" aria-label="View Post: Career In Aviation Maintenance &#8211;  jobs , salary, duties">View Post</a></div></div></div></article> <script type="application/ld+json">{"@context":"http:\/\/schema.org\/","@type":"BlogPosting","name":"Career In Aviation Maintenance &#8211;  jobs , salary, duties","url":"\/\/www.gunkrazy.com\/career-in-aviation-maintenance-jobs-salary-duties\/","articleBody":"Career In Aviation Maintenance - jobs , salary, duties\r\nThe field of aviation maintenance is changing almost as fast as the evolution of airplane and flight maintenance technology. There is a lot to know about the field, and in order to better decide if this might be the field for you \u2013 we are providing you with ten things you may not have already known about aviation maintenance.\r\n\r\nAn aircraft maintenance technician works in the commercial and public service sectors, performing a range of processes on aeronautical products. The aircraft maintenance technician has a critical responsibility to work professionally to ensure the safety of customers and maintain the reputation of the team or organization.\r\n\r\nMaintenance engineer works on jet engine at the Marka airport in Amman Jordan.\r\n\r\nThe aircraft maintenance technician normally works in an aircraft hangar. However, there are times when working outdoors is required. He or she may work for large and small organizations and occasionally directly for individual customers. He or she will undertake a number of processes including inspection, servicing, troubleshooting, removal, installation, rigging, testing and repairing. An aircraft maintenance technician may specialize by working on particular aeronautical products such as helicopters and UAVs (Unmanned Aeronautical Vehicles), and tilt wing aircraft. Whether or not he or she specializes, work organization and self-management, communication and interpersonal skills, problem-solving and the ability consistently to work safely and rigorously, adhering to industry regulations and manufacturers\u2019 instructions are the universal attributes of the outstanding aircraft maintenance technician.\r\n\r\nWhat is Aircraft Maintenance Engineering\u00a0 :\u00a0\r\n\r\nAircraft Maintenance Engineering (AME) is 4 years License program regulated by Directorate General of Civil Aviation (DGCA), Ministry of Civil Aviation, Government of India. Aircraft Maintenance Engineer are responsible for safety and security of the Aircrafts, Helicopters and other flying machines. They are specially trained to carryout complex maintenance process including periodical maintenance program as per the Aircraft manufactures requirements and issue Flight Release Certificate for safety before each flight. To carry out this maintenance process and issue Flight Release Certificate an individual has to undergo 2 years of approved training program in approved institution and two years of OJT either in any airline or MRO as per CAR 66 and CAR 147 requirements and obtain an Aircraft Maintenance Engineers License from DGCA, Ministry of Civil Aviation, Government of India.\r\n\r\nELIGIBILITY\r\nStudents who have Passed\/Appearing 10+2 (PCM) Group Candidates are eligible to apply for the Programme. 3 Years Polytechnic Diploma candidates also eligible for AME.\r\n\r\nCAREER OPPORTUNITY\r\nAME has got tremendous career opportunity in Airlines, General Aviation industry, manufacturing industry and defence sectors due to all round strong growth in Aviation Industry. The latest aviation policy of Govt. of India also highlights this fact and projects over 3.3 lacs new jobs in next few years in this sector.","headline":"Career In Aviation Maintenance &#8211;  jobs , salary, duties","author":{"@type":"Person","name":"Sachin Thorat","url":"\/\/www.gunkrazy.com\/"},"datePublished":"2018-06-07","mainEntityOfPage":"False","dateModified":"February 23, 2020","image":{"@type":"ImageObject","url":"\/\/www.gunkrazy.com\/wp-content\/uploads\/2018\/06\/What-is-Aircraft-Maintenance-Engineering--300x227.jpg","height":227,"width":300},"publisher":{"@context":"http:\/\/schema.org\/","@type":"Organization","name":"Learn Mechanical Engineering","logo":{"@type":"ImageObject","url":"\/\/www.gunkrazy.com\/wp-content\/uploads\/2020\/01\/learn-mech-logo-1-300x300.png","height":600,"width":60}}}</script> <article class="article-card horizontal "> <a href="//www.gunkrazy.com/what-is-mechanic-definition-duties-job-description/" rel="nofollow"><div class="image-container" style="background-image: url('//www.gunkrazy.com/wp-content/uploads/2018/06/mechanics-meaning-duties-300x201.jpg')"></div><span class="sr-only">link to What is Mechanic &#8211; Definition , Duties, Job Description</span></a><div class="copy-container"><header><p><a style="color: #ff392e!important" href="//www.gunkrazy.com/what-is-mechanic-definition-duties-job-description/">What is Mechanic &#8211; Definition , Duties, Job Description</a></p></header><div class="excerpt"><p>What is Mechanic - Definition , Duties, Job Description
Mechanic Definition 
Mechanic is Defined as ,  A skilled worker who repairs and maintains vehicle engines and other machinery.  e.g. a...</p><div class="button-container"><a rel="nofollow" class="button reverse" href="//www.gunkrazy.com/what-is-mechanic-definition-duties-job-description/" aria-label="View Post: What is Mechanic &#8211; Definition , Duties, Job Description">View Post</a></div></div></div></article> <script type="application/ld+json">{"@context":"http:\/\/schema.org\/","@type":"BlogPosting","name":"What is Mechanic &#8211; Definition , Duties, Job Description","url":"\/\/www.gunkrazy.com\/what-is-mechanic-definition-duties-job-description\/","articleBody":"What is Mechanic - Definition , Duties, Job Description\r\nMechanic Definition\u00a0\r\nMechanic is Defined as ,\r\n\r\n \tA skilled worker who repairs and maintains vehicle engines and other machinery.\u00a0 e.g. a car mechanic\r\n \ta craftsman skilled in operating machine tools\r\n \tsomeone whose occupation is repairing and maintaining automobiles\r\n \tA mechanic is a tradesman, craftsman, or technician who uses tools to build or repair machinery.\r\n\r\nMeaning Of Mechanics :\r\n\r\nA mechanic is a person who builds or repairs engines or other machines. Mechanics are trained to use special tools and often work in shops or garages. If you are planning to be a mechanic, you have to be prepared to get your hands dirty.\r\n\r\nThe most common type of mechanic works on vehicles like cars, motorcycles, tractors, or airplanes. If your car is making a strange noise, you should probably take it to a mechanic. The oldest meaning of this word was simply \"laborer,\" or \"person who works with his hands,\" from the Greek root mekhanikos, \"engineer.\" The current sense of mechanic came into use along with the popularity of the automobile.\r\n\r\naircraft Mechanic\r\nWhat do Mechanic do\u00a0 , Duties Of Mechanics\u00a0\r\n\r\n \tMost mechanics specialize in a particular field, such as auto mechanics, truck mechanic, bicycle mechanics, motorcycle mechanics, boiler mechanics, general mechanics, industrial maintenance mechanics (millwrights), air conditioning and refrigeration mechanics, bus mechanics, aircraft mechanics, diesel mechanics, and tank mechanics in the armed services.\r\n \tAuto mechanics, for example, have many trades within. Some may specialize in the electrical aspects, while others may specialize in the mechanical aspects.\r\n \tOther areas include: brakes and steering, suspension, automatic or manual transmission, engine repairs, or diagnosing customer complaints. An automotive technician, on the other hand, has a wide variety of topics to learn. A mechanic is typically certified by a trade association or regional government power.\r\n \tMechanics may be separated into two classes based on the type of machines they work on, heavyweight and lightweight. Heavyweight work is on larger machines or heavy equipment, such as tractors and trailers, while lightweight work is on smaller items, such as automotive engines.\r\n\r\nWhat are the education requirements to be a mechanic?\r\nA high school diploma or GED is necessary for most auto technician positions. For these entry-level positions training may be required. Some employers offer on-site training or apprenticeships, but many will want you to have successfully completed a vocational program before they hire you. These programs will provide you a combination of classroom instruction and hands-on practice so you can learn to fix any problem that comes your way.\r\n\r\nCareer paths for mechanics\r\nTypically a hard-working mechanic will be promoted to team leader or a manager position after a few years on the job. Most auto mechanic managers are grouped together into a geographic region which is led by a district manager. An ambitious and successful mechanic may be able to move into this high-level management role after working as a team leader.","headline":"What is Mechanic &#8211; Definition , Duties, Job Description","author":{"@type":"Person","name":"Sachin Thorat","url":"\/\/www.gunkrazy.com\/"},"datePublished":"2018-06-07","mainEntityOfPage":"False","dateModified":"February 23, 2020","image":{"@type":"ImageObject","url":"\/\/www.gunkrazy.com\/wp-content\/uploads\/2018\/06\/mechanics-meaning-duties-300x201.jpg","height":201,"width":300},"publisher":{"@context":"http:\/\/schema.org\/","@type":"Organization","name":"Learn Mechanical Engineering","logo":{"@type":"ImageObject","url":"\/\/www.gunkrazy.com\/wp-content\/uploads\/2020\/01\/learn-mech-logo-1-300x300.png","height":600,"width":60}}}</script> <article class="article-card horizontal "> <a href="//www.gunkrazy.com/burnishing-process-principle-advantages-and-disadvantages/" rel="nofollow"><div class="image-container" style="background-image: url('//www.gunkrazy.com/wp-content/uploads/2018/06/basic-of-operation-of-burnishing-300x229.jpg')"></div><span class="sr-only">link to Burnishing Process &#8211; Working, Diagram, Advantages, Disadvantages, Application</span></a><div class="copy-container"><header><p><a style="color: #ff392e!important" href="//www.gunkrazy.com/burnishing-process-principle-advantages-and-disadvantages/">Burnishing Process &#8211; Working, Diagram, Advantages, Disadvantages, Application</a></p></header><div class="excerpt"><p>Burnishing Process
Burnishing is a surface modification process that produces a very smooth surface finish by the planetary rotation of a tool over a bored or turned surface. The tool may consist of...</p><div class="button-container"><a rel="nofollow" class="button reverse" href="//www.gunkrazy.com/burnishing-process-principle-advantages-and-disadvantages/" aria-label="View Post: Burnishing Process &#8211; Working, Diagram, Advantages, Disadvantages, Application">View Post</a></div></div></div></article> <script type="application/ld+json">{"@context":"http:\/\/schema.org\/","@type":"BlogPosting","name":"Burnishing Process &#8211; Working, Diagram, Advantages, Disadvantages, Application","url":"\/\/www.gunkrazy.com\/burnishing-process-principle-advantages-and-disadvantages\/","articleBody":"Burnishing Process\r\nBurnishing is a surface modification process that produces a very smooth surface finish by the planetary rotation of a tool over a bored or turned surface. The tool may consist of one or more ball or roller. This process does not involve the removal of material from the workpieces. All machined or other processed metal surfaces consist of a series of peaks and valleys which constitute the surface irregularities. The force applied by the burnishing tool forces the material from the peaks to flow into the valleys. This reduces the height of the peaks and depth of the valleys, thereby reducing the surface roughness. This is shown in figure\r\n\r\nRead also: What Is Honing Machine Process used For Super Surface Finishing\r\n\r\nBurnishing is a superfinishing process of obtaining a very fine surface finish having a grainless appearance on metal objects. This process is used on various flat, cylindrical, or conical surfaces. It removes scratches and tool marks on the surface.\r\n\r\nBurnishing Definition:- Burnishing operation is the process of getting a smooth and shiny surface by contact and rubbing of the surface against the walls of the hard tools. It is a finishing and strengthening the process. Burnishing is basically a cold surface plastic deformation process.\r\n\r\nbasic of operation of burnishing\r\nPrinciple of burnishing operation\r\nBurnishing is a versatile process that improves the surface finish and dimensions of the turned parts, without the usage of extensive tooling. A conventional lathe, on which the workpieces were turned, can be used for burnishing, thereby eliminating the time and effort for remounting the workpiece. The tool used for burnishing consists of one or more ball or roller, held in a casing. This tool can be mounted on the tool post of the lathe. When the tool is made to come in contact with the rotating workpiece, the friction force rotates the balls or rollers of the tool, in a planetary motion.\r\nThe burnishing process is considered as a cold working process because the surface of the workpiece is subjected to severe stress due to the planetary motion between the tool &amp; workpiece and the pressure applied by the tool. When this stress exceeds the yield strength of the material, it results in the plastic flow of the material from the peaks of the surface irregularities into the valleys, thereby reducing the surface roughness. This also induces thermally stable and long-lasting compressive residual stresses.\r\nTypes of Burnishing Process\r\nThe burnishing process can be typically classified into two categories as follows:\r\n\r\n1) Based on deformation element\r\na) Ball burnishing\r\ni. Flexible\r\nii. Rigid\r\nb) Roller burnishing\r\n\r\n2) Based on the motion of the tool, on the surface\r\na) Normal or ordinary\r\nb) Impact\r\nc) Vibratory\r\n\r\n3. Classification based on the tool:\r\n\r\nThe burnishing process can be broadly classified into two types based on the geometry of the tool. They are\r\n1. Ball burnishing\r\n2. Roller burnishing\r\nBall Burnishing: \r\nIn this type of burnishing, the tool consists of one or more spherical balls, supported in shank by the hydraulic pressure of the fluid or spring and the reactive force of the workpiece. The schematic of ball burnishing is shown in the figure . The fluid is circulated constantly, using a hydraulic pump, through the recesses around the ball to keep it in contact with the workpiece. When the tool is fed along with the workpiece, the ball is pressed against the workpiece, resulting in the burnishing operation. The force of burnishing can be controlled by varying the hydraulic pressure of the fluid. In some ball burnishing tools, the hydraulic fluid will be replaced by a spring to control the positioning of the ball and the force applied on the workpiece.\r\n\r\nball burnishing process\r\nRoller Burnishing: \r\nRoller burnishing, as the name suggests, employs a tool with single or multiple rollers. For multiple rollers tools, the rollers are present around the circumference of a supporting shank. The figure shows the schematic of a burnishing operation with a single roller burnishing tool. The shank will be connected to the machine, which can be a drilling machine or milling machine or even a lathe. When the tool is made to come in contact with the workpiece, the rollers around the shank also rotate, resulting in the burnishing of the workpiece.\r\n\r\nroller burnishing process\r\nAdvantages and disadvantages of Burnishing :\r\nEvery manufacturing process has its own merits and demerits, which control its applicability in the industries. Burnishing also has merits and demerits, which are discussed in this section.\r\nAdvantages of Burnishing Process :\r\n1. Accurate size: \r\n\r\nParts can be produced by burnishing with high control over the dimensions. Hence very close tolerances can be achieved\r\n\r\n2. Superfine surface finish: \r\n\r\nVery smooth surfaces finish, as high as 0.05 \u03bcm Ra is possible with burnishing. The surface finish obtained is comparable with any of the other conventional surface finish operations like grinding, peening, etc.\r\n\r\n3. Improves physical properties:\r\n\r\n Burnishing produces hard, wear, and corrosion-resistant surface because of the cold rolling. It also induces compressive stresses which increase the fatigue life of the components that are subjected to cyclic loads.\r\n\r\n4. More economical: \r\n\r\nBurnishing eliminates grinding and honing, which are expensive and time-consuming processes. Burnishing can be done on any standard lathe or drill machine, which eliminates initial investment. Skilled labor is not needed for this process. Any worker who has experience in operating a lathe or drilling machine can work on the burnishing process.\r\n\r\n5. Saves time: \r\n\r\nWorkpiece loaded on a lathe, milling, or drilling machine need not be re-mounted for burnishing. The previous tool can be replaced with a burnishing tool and the process can be done on the same mount. Thus the cycle time is reduced, which increases the throughput.\r\n\r\n6. Adjustable settings: \r\n\r\nMost of the commercially available burnishing tools have adjustable settings, which increases their scope of work. This reduces the cost when any change takes place in the component design.\r\n\r\n7. Replaceable wear parts: \r\n\r\nWear parts such as roller, balls, guide rollers, etc can be easily replaced, which helps in prolonging the tool life with less maintenance cost.\r\n\r\n8. A wide variety of workpieces geometries, like flat, tapered, cylindrical, free-form surfaces can be processed by burnishing.\r\nDisadvantages of Burnishing process:\r\n1. The initial cost of the burnishing tool is high.\r\n2. Burnishing cannot be applied on miniature workpieces.\r\n3. Components with thinner walls, which do not have enough strength, cannot be burnished, because the forces applied during burnishing are generally high.\r\n4. Burnishing of intricate shapes and contours requires dedicated tools and highly skilled workmen. If the design or shapes of the contours change, a new set of tools has to be designed and manufactured. This increases the cost and time.\r\nApplication Of Burnishing :\r\n\r\n \tHydraulic system components, \r\n \tSeals, \r\n \tValves, \r\n \tSpindles, \r\n \tFillets on the shaft.\r\n \tHome Appliances\r\n \tMotors and Pump Industry\r\n\r\nBurnishing types\r\n\r\nFlat, cylindrical, or conical surfaces (both internal and external ) are burnished with hardened steel or cemented carbide rollers or with steel balls mounted in a holder, fig. Fillets and grooves are burnished by rollers rounded to a radius, Fig. Hole burnishing is performed with multi- roller tools on drill presses, turret lathes, horizontal borers, unit built machines, and automatic lathes.\u00a0\r\nDifference Between Burnishing and Broaching.\r\n\n\n\n\n\t Sr. No. Broaching Burnishing\n\n\n\n\n\t1.Broaching is material removing finishing process by using multi point broach tool.It is a Process of superfinishing, in which mirror-like\/glazed smooth surface is produced, by using ball or roller type of tool.\n\n\n\t2.It is a machining processIt is rubbing process no metal removal\n\n\n\t3.Tools have small and multiple teeth.Smooth rollers\/balls act as tool\n\n\n\t4.Pulling or pushing force is required to remove the material.Pressure is required to press the balls or rollers.\n\n\n\t5.Broaching components are- Bearing caps, cylinder blocks, connecting rods etc.Burnishing components are- Cam &amp; followers, matting parts of engine, aesthetical components etc.","headline":"Burnishing Process &#8211; Working, Diagram, Advantages, Disadvantages, Application","author":{"@type":"Person","name":"Sachin Thorat","url":"\/\/www.gunkrazy.com\/"},"datePublished":"2018-06-06","mainEntityOfPage":"False","dateModified":"August 23, 2020","image":{"@type":"ImageObject","url":"\/\/www.gunkrazy.com\/wp-content\/uploads\/2018\/06\/basic-of-operation-of-burnishing-300x229.jpg","height":229,"width":300},"publisher":{"@context":"http:\/\/schema.org\/","@type":"Organization","name":"Learn Mechanical Engineering","logo":{"@type":"ImageObject","url":"\/\/www.gunkrazy.com\/wp-content\/uploads\/2020\/01\/learn-mech-logo-1-300x300.png","height":600,"width":60}}}</script> <article class="article-card horizontal "> <a href="//www.gunkrazy.com/thermit-welding-diagram-process-advantages-and-disadvantages/" rel="nofollow"><div class="image-container" style="background-image: url('//www.gunkrazy.com/wp-content/uploads/2018/05/thermit-welding-diagram-300x149.png')"></div><span class="sr-only">link to Thermit Welding &#8211; Diagram ,Process , Advantages and Disadvantages</span></a><div class="copy-container"><header><p><a style="color: #ff392e!important" href="//www.gunkrazy.com/thermit-welding-diagram-process-advantages-and-disadvantages/">Thermit Welding &#8211; Diagram ,Process , Advantages and Disadvantages</a></p></header><div class="excerpt"><p>Thermit Welding - Diagram ,Process , Advantages and Disadvantages
Introduction to Thermit Welding:
It is a process in which a mixture of aluminium powder and a metal oxide, called Thermit, is...</p><div class="button-container"><a rel="nofollow" class="button reverse" href="//www.gunkrazy.com/thermit-welding-diagram-process-advantages-and-disadvantages/" aria-label="View Post: Thermit Welding &#8211; Diagram ,Process , Advantages and Disadvantages">View Post</a></div></div></div></article> <script type="application/ld+json">{"@context":"http:\/\/schema.org\/","@type":"BlogPosting","name":"Thermit Welding &#8211; Diagram ,Process , Advantages and Disadvantages","url":"\/\/www.gunkrazy.com\/thermit-welding-diagram-process-advantages-and-disadvantages\/","articleBody":"Thermit Welding - Diagram ,Process , Advantages and Disadvantages\r\nIntroduction to Thermit Welding:\r\nIt is a process in which a mixture of aluminium powder and a metal oxide, called Thermit, is ignited to produce the required quantity of molten metal by an exothermic non-violent reaction. The superheated metal so pro\u00adduced is poured at the desired place which on solidification results in a weld joint. It is thus a casting cum welding process.\r\n\r\nThis process has been used since 1895 for joining rails at site and for the repair and salvage of heavy castings. The process is, however, slowly going out of use due to its high cost and because of the development of more efficient, highly mechanised and less costly processes like flash butt welding and electroslag welding.\r\nProcess of Thermit Welding:\r\nThermit welding is a chemical welding process in which an exothermic chemical reaction is used to supply the essential heat energy. That reaction involves the burning of Thermit, which is a mixture of fine aluminum powder and iron oxide in the ratio of about 1:3 by weight.\r\n\r\nAlthough a temperature of 3000\u00b0C may be attained as a result of the reaction, preheating of the Thermit mixture up to about 1300\u00b0C is essential in order to start the reaction.\r\n\r\n thermit welding diagram\r\n\r\nThe mixture reacts according to the chemical reaction:\r\n\r\n8 Al + 3 Fe3O4\u00a0\u2192 9 Fe + 4 Al2O3\u00a0+ heat (3000\u02daC, 35 kJ\/kg of mixture)\r\n\r\nAluminum has greater affinity to react with oxygen; it reacts with ferric oxide to liberate pure iron and slag of aluminum oxide. Aluminum oxide floats on top of molten metal pool in the form of slag and pure iron (steel) settled below, because of large difference in densities.\r\nOperation of Thermit Welding:\r\n\r\nThermit welding process is essentially a casting and foundry process, where the metal obtained by the Thermit reaction is poured into the refractory cavity made around the joint.\r\n\r\nThe various steps involved in Thermit welding are:\r\n\r\n1. The two pieces of metal to be joined are properly cleaned and the edge is prepared.\r\n\r\n2. Then the wax is poured into the joint so that a wax pattern is formed where the weld is to be obtained.\r\n\r\n3. A moulding box is kept around the joint and refractory sand is packed carefully around the wax pattern as shown in Fig. 7.40, providing the necessary pouring basin, sprue, and riser and gating system.\r\n\r\n4. A bottom opening is provided to run off the molten wax. The wax is melted through this opening which is also used to preheat the joint. This makes it ready for welding.\r\n\r\n5. The Thermit is mixed in a crucible which is made of refractory material that can withstand the extreme high heat and pressure, produced during the chemical reaction.\r\n\r\n6. The igniter (normally barium peroxide or magnesium) is placed on top of the mixture and is lighted with a red hot metal rod or magnesium ribbon.\r\n\r\n7. The reaction takes about 30 seconds and highly super-heated molten iron is allowed to flow into the prepared mould cavity around the part to be welded.\r\nApplication and Uses of Thermit Welding:\r\nThermit welding is a very old process and now-a-days, in most cases, it is replaced by electro-slag welding. However, this process is still in use.\r\n\r\nSome applications are:\r\n\r\n(i) Thermit welding is traditionally used for the welding of very thick and heavy plates.\r\n\r\n(ii) Thermit welding is used in joining rail roads, pipes and thick steel sections.\r\n\r\n(iii) Thermit welding is also used in repairing heavy castings and gears.\r\n\r\n(iv) Thermit welding is suitable to weld large sections such as locomotive rails, ship hulls etc.\r\n\r\n(v) Thermit welding is used for welding cables made of copper.\r\nAdvantages of Thermit Welding:\r\n1. Thermit welding is a simple and fast process of joining similar or dissimilar metals.\r\n\r\n2. This process is cheap, as no costly power supply is required.\r\n\r\n3. This process can be used at the places where power supply is not available.\r\nDisadvantages of Thermit Welding:\r\n1. Thermit welding is essentially used for ferrous metal parts of heavy sections.\r\n\r\n2. It is uneconomical for welding cheap metals and light parts.","headline":"Thermit Welding &#8211; Diagram ,Process , Advantages and Disadvantages","author":{"@type":"Person","name":"Sachin Thorat","url":"\/\/www.gunkrazy.com\/"},"datePublished":"2018-06-06","mainEntityOfPage":"False","dateModified":"February 23, 2020","image":{"@type":"ImageObject","url":"\/\/www.gunkrazy.com\/wp-content\/uploads\/2018\/05\/thermit-welding-diagram-300x149.png","height":149,"width":300},"publisher":{"@context":"http:\/\/schema.org\/","@type":"Organization","name":"Learn Mechanical Engineering","logo":{"@type":"ImageObject","url":"\/\/www.gunkrazy.com\/wp-content\/uploads\/2020\/01\/learn-mech-logo-1-300x300.png","height":600,"width":60}}}</script> <article class="article-card horizontal no-thumb"><div class="copy-container"><header><p><a style="color: #ff392e!important" href="//www.gunkrazy.com/classification-of-screw-threads-application-of-screw-threads/">Classification of Screw Threads &#8211; Application Of Screw threads</a></p></header><div class="excerpt"><p>Classification of Screw Threads - Application Of Screw threads
Classification Of Screw Threads
Screw threads having various applications can be classified as follows  1. According to location  ...</p><div class="button-container"><a rel="nofollow" class="button reverse" href="//www.gunkrazy.com/classification-of-screw-threads-application-of-screw-threads/" aria-label="View Post: Classification of Screw Threads &#8211; Application Of Screw threads">View Post</a></div></div></div></article> <script type="application/ld+json">{"@context":"http:\/\/schema.org\/","@type":"BlogPosting","name":"Classification of Screw Threads &#8211; Application Of Screw threads","url":"\/\/www.gunkrazy.com\/classification-of-screw-threads-application-of-screw-threads\/","articleBody":"Classification of Screw Threads - Application Of Screw threads\r\nClassification Of Screw Threads\r\nScrew threads having various applications can be classified as follows\r\n\r\n1. According to location\r\n\r\n \texternal screw thread (on bolts etc.)\r\n \tinternal screw thread (in nuts etc.)\r\n\r\n2.According to configuration\r\n\r\n \tstraight (helical) \u2013 most common, e.g., bolts, studs etc.\r\n \ttaper (helical), e.g., in drill chuck\r\n \tradial (scroll) as in self centering chuck\r\n\r\n3 . According to the direction of the helix\r\n\r\n \tright hand (common)\r\n \tleft hand (occasionally)\r\n\r\n4. According to form\r\n\r\n \tvee thread (600 or 550 angle) \u2013 most common\r\n \tacme thread (290)\r\n \tsquare thread (generally in power screws)\r\n \tbuttress thread (45o)\r\n \tworm thread (290 ~ 400)\r\n \tsemicircular (groove section) thread being used in recirculating type bolts, screws.\r\n\r\n5. According to standard\r\n\r\n \tBSW (British Standard Whitworth); thread \u2013 size is designated by TPI (threads per inch)\r\n \tmetric thread; thread size is specified by pitch or lead (in mm)\r\n\r\n6. According to number of start\r\n\r\n \tsingle start \u2013 most common\r\n \tmulti-start (2 to 4)\r\n\r\n7. According to spacing of threads\r\n\r\n \tTPI (no. of threads per inch), e.g. 12 TPI\r\n \t\u00a0pitch (or lead) \u2013 distance between two successive threads (or length of travel of the nut for one rotation of the screw), in mm\r\n\r\n8. According to compactness or fineness of threads\r\n\r\n \tgeneral threads (with usually wide thread spacing), pipe threads (more densed desired)\r\n \tfine threads (generally for leak proof)\r\n\r\n9. According to segmentation\r\n\r\n \tfull threads (common)\r\n \thalf turns as in half nuts\r\n \tsector thread \u2013 e.g., in the jaws of lathe chucks.\r\n\r\nRead More:\u00a0Lead Screw Mechanism -types , Advantages\r\n\r\nNomenclature and Terminology used In Screw Threads\r\n\r\nGeneral Applications Of Screw Threads\r\n\r\nThe general applications of various objects having screw threads are :\r\n\u2022 fastening : screws, nut-bolts and studs having screw threads are used for temporarily fixing one part on to another part\r\n\u2022 joining : e.g., co-axial joining of rods, tubes etc. by external and internal screw threads at their ends or separate adapters\r\n\u2022 clamping : strongly holding an object by a threaded rod, e.g., in c-clamps, vices, tailstock on lathe bed etc.\r\n\u2022 controlled linear movement : e.g., travel of slides (tailstock barrel, compound slide, cross slide etc.) and work tables in milling machine, shaping machine, cnc machine tools and so on.\r\n\u2022 transmission of motion and power : e.g., lead screws of machine tools\r\n\u2022 converting rotary motion to translation : rotation of the screw causing linear travel of the nut, which have wide use in machine tool kinematic systems\r\n\u2022 position control in instruments : e.g., screws enabling precision movement of the work table in microscopes etc.\r\n\u2022 precision measurement of length : e.g., the threaded spindle of micrometers and so on.\r\n\u2022 acting as worm for obtaining slow rotation of gear or worm wheel\r\n\u2022 exerting heavy force : e.g., mechanical presses\r\n\u2022 conveying and squeezing materials : e.g., in screw conveyor, injection moulding machine, screw pump etc.\r\n\u2022 controlled automatic feeding in mass production assembly etc.","headline":"Classification of Screw Threads &#8211; Application Of Screw threads","author":{"@type":"Person","name":"Sachin Thorat","url":"\/\/www.gunkrazy.com\/"},"datePublished":"2018-06-05","mainEntityOfPage":"False","dateModified":"February 23, 2020","image":{"@type":"ImageObject","url":"","height":0,"width":0},"publisher":{"@context":"http:\/\/schema.org\/","@type":"Organization","name":"Learn Mechanical Engineering","logo":{"@type":"ImageObject","url":"\/\/www.gunkrazy.com\/wp-content\/uploads\/2020\/01\/learn-mech-logo-1-300x300.png","height":600,"width":60}}}</script> <nav class="pagination-wrapper" aria-label="article pagination"> <a class="prev page-numbers" href="?page_num=184">&laquo; PREV</a> <a class="page-numbers" href="?page_num=1"><span class="screen-reader-text">Page </span>1</a> <span class="page-numbers dots">&hellip;</span> <a class="page-numbers" href="?page_num=183"><span class="screen-reader-text">Page </span>183</a> <a class="page-numbers" href="?page_num=184"><span class="screen-reader-text">Page </span>184</a> <span aria-current="page" class="page-numbers current"><span class="screen-reader-text">Page </span>185</span> <a class="page-numbers" href="?page_num=186"><span class="screen-reader-text">Page </span>186</a> <a class="page-numbers" href="?page_num=187"><span class="screen-reader-text">Page </span>187</a> <span class="page-numbers dots">&hellip;</span> <a class="page-numbers" href="?page_num=338"><span class="screen-reader-text">Page </span>338</a> <a class="next page-numbers" href="?page_num=186">NEXT &raquo;</a></nav></section></main><aside id="secondary" class="widget-area"><div class="about-wrapper"><h2 class="widget-title" style="background: #d693c6; color: #ff392e">About Us</h2><div class="about-image" style="background-image: url('//www.gunkrazy.com/wp-content/uploads/2020/03/Sachin-Thorat-300x300-min.png')"></div><p class="about-copy">LearnMech.Com is a Mechanical Project-oriented platform run by Sachin Thorat who is a B-Tech Graduate in Mechanical Engineering. 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