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By Roger Timings, Technical author, formerly at Henley College, Coventry, UK. One of the UK's leading authors of textbooks on manufacturing and engineering.
Description This brand new textbook by one of the leading engineering authors covers basic sheet-metal fabrication and welding engineering principles
and applications in one volume - an unrivalled comprehensive coverage that reflects current working and teaching practice. It is fully
up-to-date with the latest technical information and best practice and also includes chapters on non-technical but equally essential
subjects such as health and safety, personal development and communication of technical information.
Roger Timings
covers these areas of mechanical engineering and workshop practice in a highly practical and accessible style. Hundreds of illustrations
demonstrate the practical application of the procedures described. The text includes worked examples for calculations and key points
to aid revision. Each chapter starts with learning outcome summaries and ends with exercises which can be set as assignemnts.
The coverage
is based on the SEMTA National Occupational Standards which makes this book applicable to a wide range of courses and ensures it also
acts as a vital ongoing reference source in day-to-day working practice. All students, trainees and apprentices at up to and including
Level 3 will find this book essential reading, particularly those taking:
Level 2 NVQs in Performing Engineering Operations
Level 2
and 3 NVQs in Fabrication and Welding Engineering
Level 2 NVQs in Mechanical Manufacturing Engineering
C&G 2800 Certificate and Level
3 Diplomas in Engineering and Technology
SEMTA Apprenticeships in Engineering
Audience
Students taking the Fabrication and Welding units of Level 2 and 3 engineering courses from EAL and City & Guilds. Trainee engineers in
industry: Apprenticeships at Level 2, Advanced Apprenticeships at Level 3. Courses: Performing Engineering Operations (PEO) NVQ from
EAL or C&G (2251); Applying Engineering Principles Progression Award 6983 (the Technical Certificate for the C&G PEO course); Engineering
Production 1692; Construction Services – Certificate in Welding 5990; Certificate in Fabrication & Welding Engineering 1681; Introductory
Welding Skills 3267; EAL Intermediate Certificate and Advanced Diploma in Engineering and Technology.
Contents
Chapter 1 Health and safety
1.1 Health safety and the law
1.2 Employers' responsibilities
1.3 Employees' responsibilities
1.4 Electrical Hazards
1.5 Fire fighting
1.6 Fire precautions and prevention
1.7 Accidents
1.8 First aid
1.9 Personal protection
1.10
Hazards in the workplace
1.11 Manual Lifting
1.12 Mechanical lifting equipment
1.13 Use of lifting equipment
1.14 Accessories for lifting
gear
1.15 Useful knots for fibre ropes
1.16 Inspection (lifting equipment)
1.17 Oxy-acetylene welding
1.18 Arc-welding equipment (mains
operated)
1.19 Working on site
Exercises
Chapter 2 Personal development
2.1 Basic relationships
2.2 Relationship with
managers, supervisors and instructors
2.3 Attitude and behaviour
2.4 Implementing company policy
2.5 Creating and maintaining effective
relationships with others
Exercises
Chapter 3 Engineering materials and heat treatments
3.1 States of matter
3.2 Properties
of materials
3.3 Classification of materials
3.4 Ferrous metals (plain carbon steels)
3.5 Ferrous metals (alloy steels)
3.6 Ferrous metals
(cast irons)
3.7 Abbreviations
3.8 Non-ferrous metals and alloys
3.9 The identification of metals
3.10 Non-metals (natural)
3.11 Non-metals
(synthetic)
3.12 Forms of supply
3.13 Heat treatment processes (introduction)
3.14 Heat treatment processes (safety)
3.15 The heat treatment
of plain carbon steels
3.16 The heat treatment of non-ferrous metals and alloys
3.17 Heat treatment furnaces
3.18 Temperature measurement
3.19 Atmospheric control
Exercises
Chapter 4 Using and communicating technical information
4.1 Selection of information
sources
4.2 Interpretation of information (graphical)
4.3 Interpretation of information (tables, charts and schedules)
4.4 Evaluating
engineering information
4.5 Recording and processing engineering information
4.6 Methods of record keeping
4.7 Communications (miscellaneous)
4.8 Engineering drawing (introduction)
4.9 First angle orthographic drawing
4.10 Third angle orthographic drawing
4.11 Conventions
4.12
Redundant views
4.13 Dimensioning
4.14 Welding symbols
4.15 The development of surfaces
4.16 Interpenetration
4.17 Pictorial views
Exercises
Chapter 5 Measuring and making out
5.1 Introduction
5.2 Linear measurement
5.3 Angular measurement
5.4 Correct use
of measuring equipment
5.5 Marking out equipment (tools for making lines)
5.6 Marking out equipment (tools for providing guidance)
5.7
Marking out equipment (tools for providing support)
5.8 Techniques for marking out
5.9 The need for templates
5.10 The manufacture of
templates
5.12 Condition and care of equipment
Exercises
Chapter 6 Material removal
6.1 Cutting tool principles
6.2
The application of basic cutting tool angles to hand tools
6.3 Drilling, drilling machines and routing
6.4 Shearing sheet metal
6.5 Portable
power tools
6.6 Blanking (stamping and piercing)
6.7 Flame cutting
Exercises
Chapter 7 Sheet and plate metalwork
7.1
Sheet and plate metalwork (introduction)
7.2 Roll-bending sheet metal and plate
7.3 Flow forming sheet metal
7.4 The principles of metal
spinning
7.5 Swaging sheet metal
7.6 Basic fabrication procedures
Exercises
Chapter 8 Structural steelwork and pipework
8.1 Rolled steel sections
8.2 Typical structural steel connection and assemblies
8.3 Trusses and lattice frames
8.4 Web stiffeners
8.5
Fabricated lightweight beams
8.6 Castellated beams
8.7 Pipework (setting out bends)
8.8 Pipe bending
8.9 Pipe fitting
Exercises
Chapter
9 Joining processes (mechanical connections)
9.1 Mechanical connections (threaded)
9.2 Hand reamers and reaming
9.3 Riveted
joints
9.4 Pop Diveting
9.5 Self secured joints
9.6 Folding and jointing allowance
9.7 The Pittsburgh lock
Exercises
Chapter
10 Joining processes (soldering, brazing and braze welding
10.1 Soft soldering
10.2 Soft-soldered joints using lead-free solders
10.3 Hard soldering (brazing)
10.4 Aluminium brazing
10.5 Types of brazed joints
10.6 Braze-welding
Exercises
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