LESSON 1 - Manufacturing Processes

Brno University of Technology
Faculty of Mechanical Engineering
The Institute of Manufacturing Technology
LESSON 1
Manufacturing Processes
Authors:
Ing. Miroslav PÍŠKA, PhD., Associate Professor
[email protected]
Ing. Petra CIHLÁŘOVÁ
[email protected]
Bc. Michael Lars George HILL
1
Obsah
1 Terms, Vocabulary
3
2 Examples
3
3 Exercises
5
4 References
8
2
1
Terms, Vocabulary
1)
2)
3)
2
Starting/finishing a job
transport
handling
load
finished-stock room
packing room
marking
dispatching
deliver
delivery, supply
supplier
advertising, promotion
urge
urgent
claim
complaint
Manufacturing/engineering processes
fabricating
processing
foundry processes
machining
forming
welding
joining of metals
treatment
heat treatment
surface treatment
operation
check
tool making
finishing work
quality assessment
reject, discard, waste
mender
Assembling
erect /mount/ fit/ assemble
fitter/erector
final assembly
erection, assembly
erection /assembly, fitting/ shop
dismantling
zahájení/ukončení práce
doprava, přeprava, dopravit
zacházení, manipulace
plnit, nakládat
sklad hotových výrobků
balírna
označení, značkování
vypravování, odeslání
dodávat, dopravovat, podávat
dodávka
dodavatel
reklama
urgovat
naléhavý
reklamace
stížnost
výrobní postupy, způsoby výroby
vyrábění, zhotovování
výroba, postup výroby, zpracování
slévárenské postupy
obrábění
tváření
svařování
spojování kovů
zpracování, úprava
tepelné zpracování
úprava povrchu
operace, pracovní postup
kontrola
výroba nástroj, nástrojářství
dokončovací práce
posouzení kvality
neshodný kus (zmetek)
opravitelný kus
montáž
montovat, instalovat, stavět
montér
konečná montáž
stavění, montáž
montážní dílna
rozebírání, rozmontování
Examples
LESSON 1 - MANUFACTURING PROCESSES
1. Ashok Leyland is one of India’s leading manufacturers of commercial vehicles and also manufactures
special vehicles and engines for various applications. After more than five decades as a major player in India’s commercial vehicle market, the company has provided technical innovations that have become industry
norms. The company believes strongly in working with competent suppliers that can benefit its production
performance.
2. The development of new manufacturing processes and the growing use of numerically controlled machines characterizes the present industrial production. New machines have been installed to achieve faster
processing of material. These products are ready for marketing without any further treatment. A materialflow process chart shows the sequence of all operations and inspections performed on component parts, and
their transportation, until they enter into final assembly. Machines should be grouped to use the operator’s
time most effectively. Tables of recommended speeds and feeds should always be consulted before starting a
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job.
3. The pattern is made by the pattern maker according to the drawing of the casting. There are many
types of moulding machines, all of them having their own particular applications. The mixing of the sand
and the binder is carried out either by hand or mechanically. In the cleaning department the steel castings
are taken out the moulds, sandblasted and polished.
4. Cold drawing is used in the manufacture of seamless tubes for example. Forging is the simplest method
of shaping metal to the required form. Rolling is the process of forming metal in a machine called a rolling mill.
5. In the welding shop the required details are constructed by riveting or fabricated by oxyacetylene or
electric-arc welding. Soldering is the process of joining two metals by a third metal applied in a molten state.
6. In turning various materials and works of different diameters, lathes must be run at different speeds.
If parts can be designed so that the amount of stock to be removed is within grinding limits, then grinding
is preferred and is much less costly than lathe turning. The new method resulted in a considerable saving of
labour for grinding and polishing operations, because the surfaces of the parts were not damaged.
7. Tools should be kept in locked tool cribs and should be issued only upon authorized requisitions. Tool
making is carried out in a central tool department, where expensive and less frequently used tools are also
kept.
8. This method of heat treatment, previously mentioned as giving excellent results, is being widely used
practically all over the world. The steel parts were heated too an adequate temperature and subsequently
quenched in oil.
9. Many metal objects are subjected to some form of surface treatment affecting only a thin layer of the
outer surface of the metal. Plating of metal surfaces with another metal is one of the most common methods
employed for obtaining satisfactory resistance to corrosion.
10. Polishing, painting and varnishing is the work carried out in a finishing shop. Final operation machines are located adjacent to finished stock or the final assembly shop. In the packing shop, after final
examination and practical testing, protective coats and packing are applied. The use of prefabricated parts
offers considerable advantages over their fabricating on site. When the plant is dismantled for transport, all
parts, should be attached. In the case of large machines, or where the crane facilities at the site are restricted,
it is necessary to dispatch machines in parts and to erect them on site.
11. The overhead travelling crane will be assembled at the site, this work being facilitated by special
equipment. Instructions for the mounting of the machine tools should include details of their foundations.
Details are fitted, assembled and tested in a Fitting and Sub-assembly Shop prior to delivery to the Main
Erecting Shop. If required, the services of skilled fitters can be provided for the alignment of machines on
prepared foundations. It is essential that the erection of these machines is performed in accordance with the
instructions given by the manufacturer. Special precautions for the protection of fitters during erection are
essential. In an Erecting Shop final products are assembled including sub units, received from the Fitting
and Sub-assembly Shop.
Vocabulary notes:
Process chart - diagram postupu práce; overhead travelling crane - mostový jeřáb; feed - posuv; feeding
device - plnicí zařízení; pattern - model; moulding - formování; binder - pojivo; sandblast - tryskat písek, čistit
tryskáním písku; polish - leštit, cold drawing - tažení za studena; forging - kování; rolling - válcování; welding
shop - svařovna; riveting - nýtování; electric-arc welding - svařování elektrickým obloukem; soldering - pájení
na měkko; turning - soustružení; work - zpracovávaný kus, obrobek; lathe - soustruh; stock - materiál; grinding
- broušení; tool - nástroj, soustružnický nůž; tool crib - výdejna nástrojů; quench - rychle ochladit, zakalit;
plating - pokovování; painting - natírání; varnishing - lakování; finishing shop - úpravna; protective coat ochranná vrstva, obal, plášť; packing - obal; foundation - základ, kladení základů; alignment - vyrovnání,
nastavení, seřízení.
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3
Exercises
I. Translate the following words and compose short sentences using each of them:
Subassembly, subassembly drawing,subzero treatment, subdivision, substitution, subset,subsequence, subroutine, subtotal, subsurface erosion, subcommittee, subway,suburban district, substation, sub-synchronous,subproduct,subcontractor, submerged, submarine,subnormal, subsonic speed, sub-frame, sub-cooling,subscriber,
subsider. Undercut, undermentioned, underannealead, under-saturated, under-voltage, under-valuation, underloading, under-pressure, to underestimate, underground, undershooting.
II. Translate the following expressions:
Surface treatment, hot working, resistance welding, rough machining, welded joints, inaccurate heat treatment, the treatment improving the structure of metal, liquid quenching medium, high-quality sheet steel,
steady flow of material, non-uniform heating, winding impregnation, rotor grinding, automatic feeding, removal of the pattern, laminated plastics, custom-built body, the processing of chemicals, newly coated,
permissible operating temperature, advice for unpacking, the adoption of new technology, maximum efficiency, produced from sintered fine powder, conventional technology, technologically advanced processes, fast
loading, rest for overcoming fatigue, sharpening of tools.
III. Make pairs of synonyms (expressions of similar meaning):
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
assembly shop
autogenous welding/cutting
abrasive wheel
blast air
metal casting
required electrodeposition
ground coat
hardening tank
all-automatic processing
complicated technology
finishing tool
instructions for mounting
grinder
to reduce production time
mixing apparatus
j)
a)
b)
c
d)
e)
f)
g)
h)
i)
k)
l)
m)
n)
o)
to achieve higher productivity
erection instructions
metal pouring
specified electroplating
grinding wheel
grinding machine
difficult production process
fully automatic treating
smoothing tool
stirring device
quenching tank
gas welding/cutting
blown air
erection shop
priming coat
10
1
2
3
4
5
6
7
8
9
11
12
13
14
15
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
IV. Write original sentences containing the following expressions:
To screw the nuts tight, welded construction, to be subjected to continuous heating, increased heat resistance, the greatest possible accuracy, high resistance to oxidation, to finish the surface of a work piece,
more efficient production, fairly high consumption, predetermined programme of production, to achieve improved performance, to carry out complete erection, cut into pieces, damaged in the course of the forming
process, painted in accordance with the respective standards, erection instructions provided by the manufacturer, utilization of a suitable technique, improved product, machine construction, a great amount of
scrap material, to minimize worker’s effort and lost motion, more advanced technologies, better utilization
of the floor space.
V. Complete the following sentences:
1. The whole technological process takes only . . .
2. Under these circumstances the technologists recommend . . .
3. To facilitate the erection of . . .
4. This surface treatment allows the component parts of . . .
5. The increasing technological difficulties . . .
6. The disadvantage of this process . . .
7. We adopted this method as a standard procedure for . . .
8. The melting was carried out under vacuum . . .
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9. The complete procedure divided into the following steps . . .
10. This in brief is the process known as . . .
11. The normal way of producing . . . is by . . .
12. Mounted under the same cover . . .
13. Experience accumulated in machining this alloy . . .
14. This new technology is gaining in importance . . .
VI. Read and translate the following words:
To fabricate - fabrication - fabricated - prefabricated; to treat - treatment - treated - treatable; to transport
- transportable - transportation - transporter; shape - shapeless - shaped - shaper - shaping; to form - to
transform - deformed - transformation - deformation; formability - former - forming - formless; to join joint - joiner - joinery - joining - jointed - jointless - adjoining - jointly; machine - machining - machinability
- machinable - machines - machinery - machining - machinist; to mark - marking - marked - remarkable
- remark; to dispatch - dispatching - dispatcher; to assemble - assembly - disassembly - assemblyman assembler - disassembled - assembling; to erect - erection - erector - erecting; to mount - mounting - mounted
- mounter - dismounting - dismounted - dismountable - dismountability; to fit - fitter - fitting - fittings fitted.
VII. Arrange the following expressions into pairs of words of opposite meaning:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
cold working
dissolved material
finish machining
finish coat
molten metal charge
rough file
material receiving dept.
home-made
seamless pipes
erection at the plant
disassembly of equipment
achievement of higher productivity
rapid processing
subsequent operations
regular working hours
a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
k)
l)
m)
n)
o)
time-consuming procedure
erection on the site
smoothing file
overtime work
simultaneously carried outoperations
decline in productivity
hot working
assembly of a plant
welded tubes
precipitated substance
industrially produced
rough machining
shipping department
solidified metal charge
ground coat
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
VIII. Translate the following expressions into English:
Rychlá výroba, vysoká produktivita práce, vysoký obsah uhlíku, svařované trubky, tuhnutí kovu, komplikovaný postup, slibná metoda výroby, následné vyčištění povrchu, průmyslově vyráběný, snadno obrobitelná
slitina, předchozí operace, vyrobený na zakázku, úprava vody, čerstvě natřený, bezešvé trubky, zkušený
montér, seznam náhradních dílů na skladě, odstranit nečistoty, dosáhnout vyšší produktivity, o polovinu snížit výrobní čas, pokles produktivity, zlepšení technologických postupů, výroba strojů, výrobní technologie,
zvýšená výrobní kapacita, pravidelné pracovní hodiny, uspořádání pracoviště, sled operací, únava dělníků.
IX. Explain the meaning of the following expressions:
Fundamentally new technology, flame cutting, cold rolled sheets, skilled technologists, water-hardened
part, wire drawing, low installation costs, the operations performed simultaneously, continuous casting of
steel, pure metal production, a melting furnace, permanent mould casting, erection supervisor, rules for
transport and erection, main erection bay, central passage way, the date for completion of assembly, faster
processing, recommended cutting speed, tungsten carbide tools, carbide tips, built-up area, manufacturing
space, trend of production, cutting tools, a time-consuming procedure, automatic assembly, night-shift work,
hourly production, machine time, system for issuing tools, cutting fluid, tool-life test.
X. Answer the following questions:
1. What is the purpose of heat treatment?
2. What technological processes applied in foundries do you know?
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3. What substance can be used as a quenching medium for hardening steel?
4. What operations are carried out in an assembly shop?
5. What is the difference between turning and milling?
6. What is the purpose of a material-flow process chart?
7. Can you describe the main processes applied at your works?
8. Does forging improve the structure of steel?
9. What do you know about the work of a tool department?
10. What machines are assembled or erected at the site?
XI. Translate the following sentences:
1. Produktivita práce se značně zvýšila využitím nového technologického postupu.
2. V leteckém průmyslu se při výrobě součástí pro tryskové motory používají slitiny, schopné odolat
vysokým teplotám.
3. Předpokládá se, že výsledkem zdokonalení technických postupů bude snížení výrobních nákladů.
4. Po zavedení nových výrobních postupů v tomto průmyslovém odvětví se musely provést některé změny
v organizaci závodů.
5. Čas jsou peníze.
6. Pro manipulaci s držáky nástrojů je nutno používat předepsaného nářadí.
7. Řezné nástroje se musí vyměňovat v pravidelných intervalech, aby nedošlo k havárii.
8. Hmotnost kusu byla snížena novou výrobní technologií.
9. Tato metoda povrchového zpracování by mohla mít praktický význam.
10. Kvalita znamenává obchod. Obchod znamená, že máte práci. (H. Ford)
XII. Metaphors. Make ten well-known metaphors by matching the phrases 1-10 with the
nouns A-K:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
To
To
To
To
To
To
To
To
To
To
To
run like
cry like
sleep like
drive like
sing like
smoke like
drink like
sink like
grin like
look like
feel like
A)
B)
C)
D)
E)
F)
G)
H)
I)
J)
K)
a Cheshire cat
a million dollars
a maniac
a stone
a baby
a log
an angel
the wind
a fish
a chimney
a cat on hot bricks
7
1
2
3
4
5
6
7
8
9
10
11
...
...
...
...
...
...
...
...
...
...
...
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