Workshop Processes, Practices and Materials, Third Edition

357 Pages·2004·2.05 MB·English

by  Bruce J Black CEng MIEE

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Workshop Processes,
Practices and Materials
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Workshop Processes,
Practices and
Materials
Third edition
Bruce J. Black, C. Eng., MIEE
Formerly workshop director
(wood, metal, plastics)
Gwent College of Higher Education
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Newnes
An imprint of Elsevier
Linacre House,Jordan Hill,Oxford OX2 8DP
200 Wheeler Road,Burlington,MA 01803
First published 1979
Second edition 1997
Reprinted 2001,2002,2003
Third edition 2004
Copyright ©1979,1997,2004,Bruce J. Black. All rights reserved
The right of Bruce J. Black to be identified as the author of this work
has been asserted in accordance with the Copyright,Designs and
Patents Act 1988
No part of this publication may be reproduced in any material form (including
photocopying or storing in any medium by electronic means and whether
or not transiently or incidentally to some other use of this publication) without
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British Library Cataloguing in Publication Data
A catalogue record for this book is available from the British Library
Library of Congress Cataloguing in Publication Data
A catalogue record for this book is available from the Library of Congress
ISBN 0 7506 6073 2
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Printed and bound in Meppel,The Netherlands by Krips bv.
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To my wife Gillian, children Susan and Andrew, and
grandchildren,Alexander and Thomas Hattam, Darcey, Sophie
and Bailey Black
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Contents
Preface to the first edition xi
Preface to the second edition xii
Preface to the third edition xiii
Acknowledgements xiv
1 Safe practices 1
1.1 Health and Safety at Work Act 1974 (HSW Act) 1
1.2 Health and safety organisation 1
1.3 Employer’s responsibilities 2
1.4 Safety policy 3
1.5 Safety Representatives and Safety Committees Regulations 1977 3
1.6 Employees’responsibilities 4
1.7 New regulations for health and safety at work 5
1.8 Management of Health and Safety at Work Regulations 1999 5
1.9 Provision and Use of Work Equipment Regulations 1998 (PUWER) 6
1.10 Workplace (Health,Safety and Welfare) Regulations 1992 8
1.11 Personal Protective Equipment at Work Regulations 1992 9
1.12 The Reporting of Injuries,Diseases and Dangerous
Occurrences Regulations 1995 (RIDDOR) 11
1.13 Control of Substances Hazardous to Health Regulations
2002 (COSHH) 11
1.14 Noise at Work Regulations 1989 12
1.15 Electrical hazards 14
1.16 The Health and Safety (Safety Signs and Signals) Regulations 1996 18
1.17 Safety signs and colours 18
1.18 Fire 20
1.19 First Aid at work 25
1.20 Causes of accidents 26
1.21 General health and safety precautions 26
2 Hand processes 30
2.1 Engineer’s files 30
2.2 The hacksaw 33
2.3 Cold chisels 35
2.4 Scrapers 36
2.5 Engineer’s hammers 37
2.6 Screwdrivers 38
2.7 Taps 39
2.8 Dies 40
2.9 Powered hand tools 41
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viii Contents
3 Marking out 44
3.1 Datum 44
3.2 Co-ordinates 45
3.3 Marking out equipment 46
3.4 Examples of marking out 54
4 Sheet-metal operations 61
4.1 Cutting and bending sheet metal 61
4.2 Development 65
5 Standards,measurement and gauging 70
5.1 Length 71
5.2 Dimensional deviation 78
5.3 Gauging 79
5.4 Straightness 85
5.5 Flatness 87
5.6 Squareness 88
5.7 Roundness 90
5.8 Surface roughness 92
6 Measuring equipment 95
6.1 Vernier instruments 95
6.2 Micrometers 101
6.3 Dial indicators 108
7 Cutting tools and cutting fluids 112
7.1 Cutting-tool materials 112
7.2 Cutting tools 116
7.3 Cutting-tool maintenance 122
7.4 Cutting speed 122
7.5 Cutting fluids 124
7.6 Types of cutting fluid 125
7.7 Application of cutting fluids 127
7.8 Safety in the use of cutting fluids 127
8 Drilling 129
8.1 The sensitive drilling machine 129
8.2 Tool holding 130
8.3 Clamping 132
8.4 Cutting tools on drilling machines 133
8.5 Drilling operations 136
8.6 Drilling sheet metal 138
8.7 Drilling plastics 138
9 Turning 140
9.1 Centre-lathe elements 140
9.2 Centre-lathe controls 144
9.3 Workholding 145
9.4 Centre-lathe operations 151
9.5 Taper turning 154
9.6 Screw-cutting 156
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Contents ix
10 Surface grinding 160
10.1 Elements of a surface-grinding machine 161
10.2 Controls 163
10.3 Workholding 163
10.4 Grinding wheels 165
10.5 Surface-grinding operations 171
11 Milling 174
11.1 Milling-machine elements 175
11.2 Controls 178
11.3 Milling cutters 179
11.4 Cutter mounting 182
11.5 Workholding 184
11.6 Milling operations 185
12 Joining methods 190
12.1 Mechanical fasteners 190
12.2 Screw threads 193
12.3 Locking devices 194
12.4 Riveting 197
12.5 Soft soldering 199
12.6 Solders 200
12.7 Brazing 201
12.8 Welding 203
12.9 Adhesives 205
12.10 Electrical connections 209
12.11 Relative merits of joining methods 210
13 Materials 211
13.1 Physical properties 211
13.2 Mechanical properties 214
13.3 Comparison of properties 215
13.4 Plain-carbon steel 215
13.5 Heat treatment of plain-carbon steel 217
13.6 Cast iron 220
13.7 Copper and its alloys 222
13.8 Aluminium and its alloys 223
13.9 Die-casting alloys 225
13.10 Lead 225
13.11 Contact metals 225
13.12 Bearing materials 226
13.13 Metal protection 228
13.14 Corrosion 228
13.15 Protective coatings 229
13.16 Painting 232
14 Plastics 234
14.1 Thermoplastics and thermosetting plastics 234
14.2 Types of plastics 235
14.3 Working in plastics 237
14.4 Welding 238
14.5 Machining 239