Arrange the operation stages of a typical automatic vehicle control.

a) The sensor information is processed by this controller.

b) A special sensor in the car monitors the position of the steering, accelerator and brake input devices.

c) The actions for the steering, brakes and drive subsystems are calculated.

d) This information is passed by the sensor as an electrical signal to the microprocessor controller.

 

LESSON 4

Basic Engineering Process.

1. Read and learn the new words, write them down into your vocabulary:

to pull - тягнути

in series - серія, послідовно

yield point - точка текучості металу

shearing - обрізка,

to grip – хапати

lower die -нижній штамп

upper die - верхній штамп

forming operation - операція штампування

open-die forging - кування у відкритому штампі (подкладном)

required - необхідний

hammering - кування

within - всередині

to enclose - укладати

machining -механічна обробка

rod - стрижень

tolerance - допуск

upsetting- видавлювання

blow - удар

coming - чеканка

clamp - зажим,

imprint - відбиток

hit – ударяти

Make 10 sentences with the words given above.

3. Read and translate the text:

 

TECHNOLOGICAL PROCESSES

Drawing consists of pulling metal through a die. An example of drawing is wire drawing. The diameter reduction that can be achieved in one die is limited, but several dies in series can be used to get the desired reduction.

Sheet metal forming (штамповка листового металла) is widely used when parts of certain shape and size are needed. It includes forging, bending and shearing. One characteristic of sheet metal forming is that the thickness of the sheet changes little in processing. The metal is stretched just beyond its yield point (2 to 4 percent strain) in order to retain the new shape. Bending can be done by pressing between two dies. Shearing is a cutting operation similar to that used for cloth.

Each of these processes may be used alone, but often all three are used on one part. For example, to make the roof of an automobile from a flat sheet, the edges are gripped and the piece pulled in tension over a lower die. Next an upper die is pressed over the top, finishing the forming operation (штамповку), and finally the edges are sheared off to give the final dimensions.

Forging is the shaping of a piece of metal by pushing with open or closed dies. It is usually done hot in order to reduce the required force and increase the metal's plasticity.

Open-die forging is usually done by hammering a part between two flat faces. It is used to make parts that are too big to be formed in a closed die or in cases where only a few parts are to be made. The earliest forging machines lifted a large hammer that was then dropped on the workpiece, but now air or steam hammers are used, since they allow greater control over the force and the rate of forming. The part is shaped by moving or turning it between blows.

Closed-die forging is the shaping of hot metal within the walls of two dies that come together to enclose the workpiece on all sides. The process starts with a rod or bar cut to the length needed to fill the die. Since large, complex shapes and large strains are involved, several dies may be used to go from the initial bar to the final shape. With closed dies, parts can be made to close tolerances so that little finish machining is required.

Two closed-die forging operations are given special names. They are upsetting and coining. Coining takes its name from the final stage of forming metal coins, where the desired imprint is formed on a metal disk that is pressed in a closed die. Coining involves small strains and is done cold. Upsetting involves a flow of the metal back upon itself. An example of this process is the pushing of a short length of a rod through a hole, clamping the rod, and then hitting the exposed length with a die to form the head of a nail or bolt.

 

4. Answer the questions:

1. How can the reduction of diameter in wire drawing be achieved?

2. What is sheet metal forming and where it can be used?

3. What is close-die forging?

4. What is forging?

5. What are the types of forging?

6. What types of hammers are used now?

7. Where are coining and upsetting used?

8. What process is used in wire production?

9. Describe the process of making the roof of a car.

 

5. Find the following word combinations in the text:

1. простягання металу через фільєру

2. волочіння дроту

3. зменшення діаметру

4. товщина аркуша

5. розтягувати вище за точку текучості

6. зберегти нову форму

7. краї відрізуються

8. кінцеві розміри

9. зменшити необхідне зусилля

10. збільшити пластичність металу

11. повітряні або парові молоти

12. сила і швидкість штампування

13. усередині стінок двох штампів

14. обробна обробка

15. малі допуски

6. Translate into English:

1. При волочінні дроту діаметр отвору волочильної дошки кожного разу зменшується

2. Штампування листового металу включає кування, вигин і обрізання.

3. Невелика деформація аркуша при розтягуванні допомагає зберегти нову форму деталі..

4. Зміна форми при штампуванні виробляється шляхом стискування між двома штампами.

5. Краї аркуша при штампуванні відрізуються для здобуття кінцевих розмірів.

6. При проковуванні деталь має бути гарячіше для зменшення необхідних зусиль і збільшення пластичності металу.

7. Після кування в закритих штампах деталі не требуют великої механічної обробки.

8. При чеканці деформація металу невелика і відбиток формується на поверхні металу.

9. Висадка використовується для виготовлення голівок цвяхів і болтів.

Additional text

WELDING

Welding is a process when metal parts are joined to-gether by the application of heat, pressure, or a combination of both. The processes of welding can be divided into two main groups:

• pressure welding, when the weld is achieved by pressure and

• heat welding, when the weld is achieved by heat. Heat welding is the most common welding process used today.

Nowadays welding is used instead of bolting and riveting in the construction of many types of structures, including bridges, buildings, and ships. It is also a basic process in the manufacture of machinery and in the motor and aircraft industries. It is necessary almost in all productions where metals are used.

The welding process depends greatly on the properties of the metals, the purpose of their application and the available equipment. Welding processes are classified according to the sources of heat and pressure used: gas welding, arc welding, and resistance welding. Other joining processes are laser welding, and electron-beam welding.

Gas Welding

Gas welding is a non-pressure process using heat from a gas flame. The flame is applied directly to the metal edges to be joined and simultaneously to a filler metal in the form of wire or rod, called the welding rod, which is melted to the joint. Gas welding has the advantage of using equipment that is portable and does not require an electric power source. The surfaces to be welded and the welding rod are coated with flux, a fusible material that shields the material from air, which would result in a defective weld.

Arc Welding

Arc-welding is the most important welding process for joining steels. It requires a continuous supply of either direct or alternating electrical current. This current is used to create an electric arc, which generates enough heat to melt metal and create a weld.

Arc welding has several advantages over other welding methods. Arc welding is faster because the concentration of heat is high. Also, fluxes are not necessary in certain methods of arc welding. The most widely used arc-welding processes are shielded metal arc, gas-tungsten arc, gas- metal arc, and submerged arc.

Resistance Welding

In resistance welding, heat is obtained from the resistance of metal to the flow of an electric current. Electrodes are clamped on each side of the parts to be welded, the parts are subjected to great pressure, and a heavy current is applied for a short period of time. The point where the two metals touch creates resistance to the flow of current. This resistance causes heat, which melts the metals and creates the weld. Resistance welding is widely employed in many fields of sheet metal or wire manufacturing and is often used for welds made by automatic or semi-automatic [«semi «Ltq'mxtlkJ machines especially in automobile industry.

 

Essential Vocabulary:

pressure welding –зварка тиском

heat welding -зварка нагріванням

instead -замість

bolting – кріплення болтами

riveting – клепка

basic – основний

to manufacture - виготовляти

to depend – залежати від

purpos e - мета

gas welding -газозварка

arc welding -єлектродугова зварка

resistance welding - контактна зварка

laser welding –лазерна зварка

electron-beam welding - електронно-променева зварка

flame – полум’я

edge - край

simultaneously- одночасно

filler - наповнювач

wire - дріт

rod - прут, стержень

to melt - плавити(ся)

joint - з'єднання, стик

coated - покритий

flux - флюс

to shield – затуляти

fusible - плавкий

touching - торкання

tip – кінчик

 

8. Answer the questions:

1. How can a process of welding be defined?

2. What are the two main groups of processes of welding?

3. How can we join metal parts together?

4. What is welding used for nowadays?

5. Where is welding necessary?

6. What do the welding processes of today include?

7. What are the principles of gas welding?

8. What kinds of welding can be used for joining steels?

9. What does arc welding require?

10. What is the difference between the arc welding and shielded-metal welding?

 

9. Find the following words and word combi-nations in the text:

1. зварка тиском

2. теплова зварка

3. болтове (клепане) з'єднання

4. процес зварки

5. залежати від властивостей металів

6. наявне устаткування

7. зварювальний електрод

8. плавкий матеріал

9. дефектний зварний шов

10. безперервна подача електричного струму

11. електрична дуга

12. джерело електричного струму