Engineering Fundamentals

•A comprehensive general engineering text for vocational students, apprentices and trainees•Provides knowledge and understanding required for competence-based courses•Builds on the success of Roger Timings' classic engineering textsA comprehensive introduction to engineering for students, apprentices and trainees.All students following a vocational course in general or mechanical engineering will appreciate the wealth of engineering knowledge and know-how that has gone into this book. The underpinning knowledge for a wide range of courses and competence-based assessments is provided here in one volume, along with detailed information on the practical techniques, health and safety considerations and best working practice that go to make a successful engineer. The wide scope of this book makes it an ideal core text for many courses and apprenticeship schemes worldwide.The coverage matches the following UK courses: Mechanical Engineering NVQs - Performing Engineering Operations NVQ schemes (EMTA and C&G 2251), Basic Engineering Competences (C&G 2010), Mechanical Production Competences (C&G 2280). It is also designed to provide underpinning knowledge for Foundation Modern Apprentice and Modern Apprentice schemes. The coverage is also appropriate for mechanical engineering units from Edexcel.Engineering Fundamentals is designed to meet the latest course requirements, and brings together the essential material from Roger Timings' previous engineering texts: Fundamentals of Mechanical Engineering, Fundamentals of Engineering, Basic Engineering Technology and General Engineering.A highly readable text is supported by numerous illustrations,learning objectives and exercises at the end of each chapter, making Engineering Fundamentals a complete student-focused course that is ideal for classroom, workshop and independent study. 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 Engineering Fundamentals is designed to meet the latest course requirements, and brings together the essential material from Roger Timings previous engineering texts: Fundamentals of Mechanical Engineering, Fundamentals of Engineering, Basic Engineering Technology and General Engineering. A highly readable text is supported by numerous illustrations, learning objectives and exercises at the end of each chapter, making Engineering Fundamentals a complete student-focused course that is ideal for classroom, workshop and independent study. *A comprehensive general engineering text for vocational students, apprentices and trainees*Provides knowledge and understanding required for competence-based courses*Builds on the success of Roger Timings classic engineering texts General health and safety Establishing effective working relationships Handling engineering information Engineering materials and heat treatment Engineering drawing Measuring Marking out Basic bench fitting Drilling techniques and drilling machines Centre lathe and turning techniques Milling machines and milling techniques Grinding machines and processes. Supported by illustrations, learning objectives and exercises at the end of each chapter, this is a student-focused course that is suitable for classroom, workshop and independent study. It serves as a comprehensive general engineering text for vocational students, apprentices and trainees.