Unit 4 (Total Score – 67 points) forging processes ( II )

I. Read and memoraze the following words: (Score – 31 points)

hardier	ковальське зубило
cut of	відрубка
groove	канавка, прорізь
surplus	залишок
crimping	гофрирування
pein hammer	слюсарний молоток
bick	ковалдо
fuller	чеканка
sledge hammer	кувалда, ковальський молот
set hammer	рихтувальний молоток
flatter	правильний молоток
thickness	товщина
forged welding	ковальське зварювання
joint weld	зварочний шов,
scarf weld	зварочне з`єднання внапуск
to split	розколювати
upset	висадка,осаджувати
flux	потік
dissolve	розчиняти
scale	окалина,нагар
commencement	сорозмір, пропорційність
to tap	легенько вдаряти
split	з’єднання (врасщеп)
straight	з’єднання без шпунків й шпонок
welded joint	зварочне з`єднання
upsetter	розковування, осаджування
wrought	кований
bring	доводити
borax-based	бура
hammering	ковка, чеканка
upset weld	зварювання

Forging Processes (II) (Score – 6 points)

Cutting off on a hardie

The length of material required for a job may be cut off by striking it onto a hardie which fits into the hardie hole in the anvil. As shown in the diagrams opposite the heated metal is turned as it is hammered onto the cutting edge of the hardie, forming a deep groove all the way around. When the groove is sufficiently deep the metal may be broken off by bending it over the edge of the anvil.

Methods of crimping

To reduce the section of a bar without causing an increase in the width of the material the surplus material must be moved along the bar, resulting in an increase in length. This move­ment of the metal is achieved by crimping and three methods are shown.

A. The bar is heated, held against the edge of the anvil and struck with a straight pein hammer at intervals along the length of material to be reduced.

B. Larger sections of material can be crimped by hammering the heated metal onto the bick of the anvil.

C. Deeper crimping will be best achieved by two people working together, using a pair of fullers. The bottom fuller fits into the hardie hole in the anvil and the top fuller is struck with a sledge hammer.

Drawing down parallel

After crimping the surfaces of the metal need to be flattened and this work is carried out on the face of the anvil. The set hammer or the flatter are placed onto the heated metal and struck with a sledge hammer to flatten the metal to the required thickness.

Forged welding

With the metal at white heat a welded joint can be made by hammering two pieces of metal together. The process requires skill and judgement to achieve a successful joint and the correct procedure must be followed.

The joint point shown in the diagrams are used to join material in length ; the scarf weld being used to join small round or square stock and the split weld being suitable for thicker material which has sufficient section to be split. Firstly, the ends to be welded must be upset to provide a surplus of material and prepared to shape as required by the weld. The ends are then brought near to the welding temperature, removed from the fire and fluxed. The purpose of the flux is to dissolve any scale that may have formed on the surface of the heated metal and to prevent further oxidation. Sand is used as the flux when welding wrought iron and a borax based flux for mild steel. The metal is returned to the fire to heat to the welding temperature and when white heat is reached the welding operation must be carried out very quickly. The weld is achieved by hammering the metal on the face of the anvil and speed is essential so that the pieces may be joined before the heat is lost. (Between the removal of the metal from the fire and the commencement of hammering the metal should be tapped on the anvil to remove any scale which may have formed.) A second heating is usually necessary to allow the welded joint to be hammered to shape.

II. Choose the English equivalents from the text. (Score – 10 points)

1. зварювати; 2. гартування; 3. розчиняти; 4. рихтувальний молот; 5. потік; 6. окалина; 7. бура; 8. висадка; 9. розколювати; 10. гофрирування

III. Complete the sentences: (Score – 10 points)

1. This movement of the metal is achieved …

2. Larger sections of material can be crimped by…

3. After crimping the surfaces of the metal need to be flattened and this work is carried out on…..

4. The process requires …to achieve a successful joint.

5. A second heating is necessary to allow ….

6. A welded joint can be made by ...

7. The purpose of the flux is….

8. Sand is used as a flux when ...

9. The metal is returned to the fire to….

10. Between the removal of the metal from the fire and the commencement of hammering the metal should…

III. Name the forging processes you know. (Score – 6 points)

IV. Retell the text in your native language. (Score – 6 points)

U NIT 5 (Total Score – 51 points)

I. Read and memorize the following words: (Score – 110 points)

to anneal	віджимати,обпалювати
craft	майстерність,ремесло
to involve	охоплювати, утягувати
beating	биття
malleable	ковкий
sheet form	листова форма
mallet	дерев’яний молоток, киянка
gliding	сковзання, плавний рух
brass	латунь
bending	згин
to facilitate	сприяти
shaping process	формування
soft	м’який, пластичний
to harden	гартувати
dull	тусклий, матовий
quenching	гартування, охолодження
to cool	охолоджувати
dry quenching	сухе охолодження
surface	поверхня
to dip	занурювати
dilute	розчин
sulphuric acid	сірчана кислота
pickle	солити, травити
pumice	пемза
scour	чищення, промивання
powder	порошок
rinse	полоскати, промивати
blank	заготівка
snips	ножиці
file	напилок
smooth	рівний, гладенький
to remove	усувати
scratch	подряпина, дряпати
shaping	формування, обробка тиском
commence	починати
depend on	залежати від
diagram	схема, діаграма
sinking	заглиблення
shallow	дрібний
tray	піддон, кошик
flat rim	край
dish	чаша
bossing mallet	опуклий молоток
blocking	блокуючий
block hammer	молот з падаючою бабой
stepped	з виступами
hardwood	тверда древесина
block	колода, брусок
nail	цвях
dowel	штир
fit	приладнати (усередину)
rim	край
step	виступ
flatten	рихтувати
turn	обертати
hollowing	заглиблення, розточка
raising	чеканка, рельєфний
to contrack	тиснити,стягувати
domed	опуклий
stake	стойка
pinch	тиснення
ram	штемпель, баба
drawing	волочіння
boring	розточка
sheet press work	листове штампування
stretch forming	згинання,розтяжіння
riveting	клепка
welding	варка
edge	кромка
allowance	припуск (під обробку)
cutting edge	гострий край
grinding	протягування
rolling	прокат
mechanical working	обробка тиском
ingot	злиток
billet	заготівка
straightening	правка
setting	осадка