Металлы и металлорежущие станки

Л. И. Воскресенская

И. А. Рожнова

 

 

МЕТАЛЛЫ И МЕТАЛЛОРЕЖУЩИЕ СТАНКИ

METALS AND METAL-CUTTING MACHINE-TOOLS

Учебное пособие по английскому языку

 

 

Омск

Издательство ОмГТУ

УДК 811.111:669+621.9(075)

ББК 81.2Анг+34.431+34.63-5я73

В 76

 

 

Рецензенты:

В. П. Сороколетов, канд. филол. наук, доцент, декан факультета
иностранных языков ОмГПУ;

К. Ю. Симонова, канд. филол. наук, доцент, зав. кафедрой
«Иностранные языки» СибГУФК

 

Воскресенская, Л. И.

В 76 Металлы и металлорежущие станки = Metals And Metal-Cutting Machine-Tools: учеб. пособие по английскому языку / Л.И. Воскресенская, И.А. Рожнова.– Омск: Изд-во ОмГТУ, 2009. – 60 c.

 

 

Целью данного пособия является обучение студентов чтению и переводу литературы по специальности «Металлорежущие станки» машиностроительного факультета (института). Оригинальные тексты содержат информацию о типах металлов, сплавов, их свойствах, способах обработки и сферах применения.

В пособии описываются различные типы станков: токарный, сверлильный, винторезный, фрезерный и станки с ЧПУ. Описываются устройство станков и принципы их действия.

Система предтекстовых и послетекстовых упражнений способствует усвоению способов словообразования, терминологии специальности, а также развитию навыков говорения по основным аспектам специальности.

Пособие предназначено для студентов II курса машиностроительных специальностей.

Печатается по решению редакционного-издательского совета

Омского государственного технического университета.

УДК 811.111:669+621.9(075)

ББК 81.2Анг+34.431+34.63-5я73

 

 

© ГОУ ВПО «Омский государственный

технический университет», 2009

Contents

Part I. Metals

Section I. Metals in Periodic Table............................................................... 4

Section II. Types of Metals............................................................................ 9

Section III. Metals and Alloys.................................................................... 14

Section IV. Steels......................................................................................... 19

Section V. Fabrication of Metals................................................................ 24

 

Part II. Metal-cutting Machine Tools

Introduction. Machine Tools...................................................................... 29

Section I. Drill Press.................................................................................... 33

Section II. Lathe........................................................................................... 39

Section III. Screw Machines........................................................................ 42

Section IV. Milling Machines..................................................................... 47

Section V. Numerical Control..................................................................... 51

 

Библиографический список...................................................................... 57

Part I. Metals

Text

Read the text dealing with discovery of metals and opening the Periodic Law

Metals in Periodic Table

Chemical elements were being studied for a long time in the middle of thе 18^th century. French scientist Lavoisier laid the foundation of the chemical science, having started the quantitative analysis of the elements. Early in the 19^th century English chemist John Dalton tried to establish the atomic theory. By the middle of the 19^th century chemical elements had been classified into two general groups: metals and non-metals.

The step forward during this period was the idea of new concept called “valence”, which meant the capacity of atoms to combine with one another. Later, it was found that the properties of chemical elements depend on their atomic weight. So, a Russian scientist D. I. Mendeleyev (1834–1907) could build up a periodic classification of all the then known elements. According to his theory, Mendeleyev predicted the properties of some undiscovered elements for which he left blank spaces. The theory became true and in 1875 such elements as gallium was discovered, taking the place below zinc. Scandium was discovered in 1879, filling the gap below calcium and germanium – in 1886, taking the place near gallium, below zinc. In the memory of the originator of the Periodic Law the 101^st element discovered by American scientists in 1951 was named mendeleyevum. Mendeleyev’s Periodic law is regarded to be one of the most recognized and important achievements in science.

D. I. Mendeleyev was not the only Russian scientist dealing with metals. M. V. Lomonosov formulated the first definition of the word “metal” in the following way: “A metal is a bright solid that can be forged”. Besides, the characteristic features of metals are lustre, toughness, workability, electrical and heat conductivity and others. Metals are well processed materials. They can be cast, forged, stamped, extruded, rolled, cut, welded.

It is the presence of iron that divides metals into ferrous and non-ferrous. And it is by this reason that iron may be considered to be the most important element in Periodic Table. The abundance in which iron is founded, its great strength, its remarkable ductility and malleability make it specially suitable for many works where strength with lightness are required. However, in ancient states the use of iron, either cast or wrought, was rather limited, bronze being the favourite metal almost for all purposes. Bronze is known to be the alloy of copper and tin.

Bronze and other non–ferrous metals, such as gold and silver, may be treated in various ways, the chief of which are: casting in mould and treatment by hammering and punching. Along with bronze brass (an alloy of copper and zinc) is widely used because of its cheapness in comparison with bronze. Besides, analyses of the iron of prehistoric weapons showed that they contained a considerable percentage of nickel. And in many specimens of ancient bronze, small quantities of silver, lead and zinc were also found.

It is worth mentioning that both ferrous and non-ferrous metals are widely used in a great variety of works and non-ferrous materials are predominant in works of art. Many metals of Periodic Table can interact with each other and develop quite new materials and alloys. For example, aluminium oxide which is also referred to as corundum, sapphire, ruby or aloxite are mentioned in the mining, ceramic and materials science. Rubies are given their characteristic deep red colour and laser qualities by adding such metallic element as chromium. Sapphires come in different colours given by impurities of iron and titanium. Aluminium oxide is widely used in the fa­
brication of superconducting devices, particularly single electron transistors and superconducting quantum interference devices (SQUID).

Such metals as boron and nitrogen form boron nitride known as Borazon. The latter is a crystal created by heating equal quantities of boron and nitrogen at temperatures greater than 1800⁰C (3300 F) at 7 GPa (1 million lbf/in²). Borazon replaced aluminium oxide for grinding hardened steels due to its far superior abrasive properties. Other uses include jewellery designing, glass cutting and laceration of diamonds.

 

Exercise 3 . Complete the sentences:

1. Chemist who established the atomic theory was…

2. There are two general groups of metals:…

3. The capacity of atoms to combine with one another is called…

4. For undiscovered elements Mendeleyev left…

5. The 101^st element was named in the memory of …

6. The most important element in Periodic Table is…

7. In ancient works of art the most widely spread metal (alloy) was…

8. Aluminium oxide is widely used in …

9. Borazon replaced aluminium oxide due to …

 

Exercise 4 . Insert the proper words into the sentences:

1. Chemists found a new (понятие) called (валентность).

2. (Свойства) of chemical elements (зависеть от) their (атомный вес).

3. According to Mendeleyev’s theory it is possible (предсказать) the properties of elements.

4. Lomonosov gave the first (определение) of metal.

5. Iron owing to its (эластичность) and (ковкость) is widely used metal.

6. Bronze is (сплав) of copper and tin.

7. In many (образец) of ancient bronze some (примесь) of other metals have been found.

8. (Цветные металлы) are mainly used in works of art.

9. Aluminium adds (сверхпроводимость) to its alloys.

10. Borazon is used for (шлифовать) hardened steels.

Exercise 5 . Find in the text the sentences that correspond to the following statements:

1. In the middle of 19^th century classification of chemical elements appeared.

2. Due to the quantitative analysis of chemical elements new concept emerged.

3. Mendeleyev’s theory gave the opportunity to foresee the properties of elements.

4. Gradually several elements which filled the gaps in the Table were discovered.

5. Metals can be processed by various operations.

6. Owing to its qualities iron is the most important element in the Table.

7. Earlier the most popular metal was bronze.

8. Ancient weapons contained impurities of several non-ferrous metals.

9. Interaction of metals can result in other materials and alloys.

10. Such metal as boron possesses high strength and is used for grinding hardened steels and cutting diamonds.

 

Exercise 6 . Translate into English:

1. Количественный анализ элементов, придуманный французским ученым Лавуазье, стал основой химической науки.

2. Понятие валентности означает способность атомов соединяться друг с другом.

3. Атомная теория Джона Дальтона была подтверждена русским ученым Менделеевым.

4. Свойства химических элементов зависят от их атомного веса.

5. Предсказанные свойства неоткрытых элементов подтвердились.

6. В результате новые элементы заполнили пропуски в таблице.

7. Один из вновь открытых элементов был назван в честь создателя периодической таблицы.

8. Одно из определений слова «металл» было дано Ломоносовым.

9. Основными свойствами металлов являются: прочность, эластичность, ковкость, электро- и теплопроводность.

10. Металлы могут быть обработаны ковкой, штамповкой, прокаткой, резанием, сваркой и другими способами.

11. Металлы делятся на цветные и черные и могут взаимодействовать друг с другом, образуя сплавы.

 

Speaking:

Exercise 7 . Give the summary of the text, using key vocabulary and tell about:

a) scientists engaged in chemical science;

b) atomic theory;

c) discovery of unknown elements;

d) characteristic features of metals;

e) the ways of processing metals;

f) ability of metals to interact with each other.

 

Checklist for Section I:

1. How is Absolute Participle Construction translated into Russian?

2. What are the suffixes of abstract nouns?

3. What were the preconditions of appearing Periodic Table?

4. What are the main properties of metals?

5. How can metals be processed?

 

Section II. Types of Metals

Grammar: Passive Voice.

Word-formation: Suffixes of adjectives – ant, -ive, -full, -less.

Speaking: Characteristics of metals.

Practise the reading of the words:

specific	[spI′sIfIk]
environmental	[In′vaIərənməntl]
corrosion	[kə′rouჳən]
chromium	[′kroumjəm]
cobalt	[kə′bɔ:lt]

 

Learn the pronunciation and meaning of the words:

failure	[′feIljə]	авария, повреждение
formability		обрабатываемость
drawback		недостаток
density		плотность
pure	[pjuə]	чистый
pig iron		чугун (в болванках)
cast iron		чугун (расплавленный)
scrap		лом, отходы
puddling	[′pΛdlIη]	пудлингование
tungsten	[′tΛηstən]	вольфрам
lead	[led]	свинец
alkali	[′ælkəlaI]	щелочь
sulfuric acid	[sΛl′fjuərIk]	серная кислота
hydrochloric acid		соляная кислота
crankshaft		коленчатый вал
gear		шестерня

Vocabulary development: word building:

Exercise 1 . Translate the original and derivative words, using a dictionary and create several new words by adding suffixes:

verb	noun (abstract)	noun (personal)	adjective
to resist	resistance	-	resistant resistible resistive
to prevent	prevention preventer	-	preventive
производить	production product productivity	производитель	producible productive
to use	использование	user	useful useless usable
to apply	application appliance	applicant	применяемый
to modify	modification	-	modificatory modifiable
отличаться	variety variability variance variant	-	various variable variant varied
to destruct	destruction	-	destructive

Exercise 2 . Translate word combinations with the verbs in Passive Voice and define their tense:

engineering industry is based on…; metallic materials are divided into…; some materials are categorized as…; the main difference is based on…; ferrous materials are produced in large quantities; non-ferrous materials can be easily fabricated; the term “pure metal” is used for…; all chemical elements but one are eliminated; the designation “metal” is applied to…; almost all impurities have been removed; steel may be shortly defined as…; to non-ferrous metals are referred…; the requirements are met…; vanadium was discovered…

 

Text

Read the text telling about various types of metals:

Types of Metals

All engineering industry is based on processing and application of metals. The selection of material can play very important role in terms of their qualities to prevent failures. Selection of material for a specific purposes depends on many factors. Some of the most important ones are: strength, ease of forming, and resistance to environmental destruction.

Metallic materials are broadly divided into two types – ferrous and non-ferrous ones. Ferrous materials are those in which iron (Fe) is the principle constituent. All other materials are categorized as non-ferrous materials. The main difference between both types of metals is based on their formability.

Ferrous materials are produced in large quantities. One main drawback of ferrous alloys is their environmental destruction, i.e. poor corrosion resistance. Other disadvantages include: relatively high density and comparatively low electrical and thermal conductivities.

Non-ferrous materials have specific advantages over ferrous ones. They can be easily fabricated, have relatively low density, and high electrical and thermal conductivities. However, different materials have distinct characteristics, and are used for specific purposes.

The term “pure metal” is used for materials in which almost all chemical elements, but one are eliminated. The designation “metal” is applied to any metallic materials in which metallic lustre and the ability for plastic deformation being characteristic features.

To ferrous metals belong: pig iron, cast iron, wrought iron, steel and others. Pig iron is the starting material in the production of all ferrous metals. It contains iron as the main ingredient, the impurities being carbon, silicon, manganese, sulphur and phosphorus. Cast iron is the pig iron modified in structure by remelting it with addition of steel scrap. Wrought iron is the iron from which almost all impurities of carbon, sulphur, phosphorus and other have been removed by the process known as puddling. Steel may be shortly defined as an alloy of iron and carbon. The chief alloying elements used being nickel, chromium, molybdenum, silicon, vanadium, tungsten, cobalt and copper.

To non-ferrous metals are referred: gold, silver, aluminium, copper, lead, zinc, mercury, magnesium, titanium, nickel, chromium, molybdenum, vanadium, tungsten, cobalt.

Some of these are the ingredients of cutting-tool materials which must combine strength, toughness, hardness, and wear resistance at elevated temperatures. These requirements are met in varying degrees by carbon steels (containing from 1 to 1,2 per cent of carbon), high-speed steels (iron alloys containing tungsten, chromium, vanadium and carbon), tungsten carbide and aluminium oxide.

Let’s consider one of the mentioned metals – Vanadium. It is the chemical element with the symbol V and atomic number 23. Vanadium was discovered in 1801, but renamed by its modern name in 1831. It is a soft, silvery, grey, ductile transition metal. It has good resistance to corrosion and is stable against alkalis, sulfuric and hydrochloric acids. Vanadium is used in the form of ferrovanadium as an additive to improve steels. The considerable increase of strength in steel containing small amounts of vanadium was the reason for using it for applications in axles, bicycle frames, crankshafts, gear, and other critical components.

 

Exercise 3 . Complete the sentences:

1. The selection of material is important to prevent…

2. Metallic materials are divided into…

3. Iron is the principle constituent in…

4. Beside ferrous materials, all other are categorized as…

5. The main drawback of ferrous alloys is …

6. Different materials have distinct…

7. To ferrous metals belong…

8. Steel may be defined as…

9. To non-ferrous metals are referred…

10. The strength of steel was the reason for…

 

Exercise 4 . Insert the proper words into the sentences:

1. The selection of material is important (с точки зрения) their qualities.

2. One of the most important quality is (сопротивление) to (окружающая среда) destruction.

3. Iron is (главный составляющий) of ferrous materials.

4. The main difference in the types of metals is their (обрабатываемость).

5. One of the drawbacks of ferrous metals is poor (сопротивление к коррозии).

6. The designation “metal” (применяется) to metallic materials with specific (свойствами, характеристиками).

7. Most of the non-ferrous metals are (составная часть) of (режущий) materials.

8. Vanadium has good (сопротивляемость к коррозии и кислотам).

9. Vanadium as (добавка) (улучшать) the (свойства) of steels.

10. The strength of steel is the reason of its (применение) in (коленчатый вал) and (шестерня).

Exercise 5 . Find in the text the sentences that correspond to the following statements:

1. The choice of material is very important factor in machinery.

2. Strength, formability and corrosion resistance are the most important features.

3. Iron is the main ingredient of ferrous materials.

4. High density and low conductivity are the drawbacks of ferrous metals.

5. The word “metal” is used referring to metallic materials possessing specific characteristics.

6. Alloying ingredients of steel are the majority of non-ferrous metals.

7. Tools for processing materials should be strong, hard and wear resistant.

8. Carbon steels meet the requirements necessary for cutting- tool materials.

9. Some metals are resistant not only to corrosion but to acids.

10. Many metals are used in parts where strength is needed.

 

Exercise 6 . Translate into English:

1. Машиностроение имеет дело с обработкой различных металлов.

2. Металлы должны обладать такими качествами, как прочность, ковкость, обрабатываемость.

3. Черные и цветные металлы обладают различными свойствами.

4. Недостатком черных металлов является их низкая сопротивляемость коррозии.

5. Цветные металлы имеют низкую плотность и легко обрабатываются.

6. Термин «чистый металл» означает материал, в котором содержится только один элемент.

7. Отличительной чертой металлов является блеск, тягучесть и способность к пластической деформации.

8. К черным металлам относятся чугун, литой чугун, сварочное железо и стали.

9. Элементами сплавов, как правило, являются никель, хром, молибден, ванадий, вольфрам, кобальт и другие.

10. К цветным металлам относятся алюминий, золото, серебро, медь, магний, титан, ртуть и другие.

 

Speaking:

Exercise 7 . Give the summary of the text, using key vocabulary and tell about:

a) division of metallic materials into groups;

b) qualities of ferrous metals;

c) characteristics of non-ferrous metals;

d) what materials can be alloying elements;

e) the role of alloying elements.

 

Checklist for Section II:

1. What are the Tense forms of Passive Voice?

2. What is the meaning of suffixes – ful and - less?

3. What are ferrous and non-ferrous metals?

4. What are characteristic features of these groups?

 

Text

Read the text about the properties of some metals resulting in alloys:

Metals and Alloys

Each metal possesses certain distinct combinations of properties, that may be varied for specific engineering applications by alloying it with relatively, small amounts of other materials. The term “alloy” is used to determine a material containing more than one chemical element. The properties of the alloy being determined by the properties of the elements it consists of. The main alloying element in ferrous metals is carbon (C). Depending on the amount of carbon, alloys have different properties. The carbon content may be either less or higher than 2,14 %. Below this amount of carbon material undergoes hard cast eutectoid* transformation, while above that limit ferrous materials undergo easy cast eutectic** transformation. The ferrous alloys with less than 2,14 % C are termed as steels, and the ferrous alloys with higher than 2,14 % C are termed as cast irons.

Steels are alloys of iron and carbon with other alloying elements. Steels can be low, medium and high carbon. Cast irons may contain 3.0–4.5 % C along with some other alloying additions and melt at lower temperatures than steels. Cast irons are specified as gray, white, nodular and malleable cast irons.

Gray cast iron consists of carbon in the form of graphite flakes, which are surrounded by either ferrite or pearlite. Although gray cast irons are weak and brittle they possess good damping properties and are applied in base structures, beds for heavy machines as they have high resistance to wear.

White cast irons are very brittle. Hence their use is limited to wear resistant applications, such as rollers in rolling mills. Usually white cast iron is heat treated to produce malleable iron.

Malleable cast irons are stronger and possess high amount of ductility. Their typical application include railroad, connecting rods, marine and other heavy-duty services.

Nodular (or ductile) cast irons are stronger and more ductile than gray cast irons. Their applications are pump bodies, crank shafts, automotive components, etc.

Non-ferrous alloys are also widely used in engineering.

Aluminium alloys are characterized by low density, high thermal and electrical conductivities, good corrosion resistant characteristics. But the great limitation of these alloys is their low melting point (660 єC). Aluminium alloys with Lithium (Li), Magnesium (Mg) and Titanium (Ti) are paid much attention when vehicle weight reduction is concerned. They are very useful in aircraft and aerospace industries. Common applications of Al alloys include: beverage cans, automotive parts, bus bodies.

It is worth mentioning that aluminium alloys are used where light weight is needed. They are also used because of their resistance to corrosion. Aluminium alloys also possess desirable property of thermal and electrical conductivity.

Beside aluminium alloys there are some other non-ferrous ones: copper, lead, tin, zinc, nickel alloys. It is necessary to point out that both ferrous and non-ferrous metals possess many characteristic features: elasticity, ductility, malleability, toughness, brittleness, hardness, wear resistance and corrosion resistance. Copper alloys form such metals, as brass and bronze. The aluminium alloys with copper, manganese, silicon and nickel are widely used where corrosion resistance, high electrical conductivity, ductility and high strength are needed. Zinc alloys have some advantages over others in foundry: excellent casting properties, machinability and lower density than bronze.

In machinery there is one of the most interesting metals, called titanium. Titanium has wonderful property – it is completely inert in biological media and that is why is being widely used in medical purposes for making artificial joints and surgery instruments. Owing to its high corrosion resistance, lightness, tensile strength and ease of forging, rolling and stamping titanium is used in a great variety of fields. Titanium alloys are applied in mechanical engineering, medical and chemical areas.

Alloying elements are added to achieve certain properties in the material. Alloying elements are added in lower percentages (less than 5 %) to increase strength or hardenability, or in larger percentages (over 5 %) to achieve special properties, such as corrosion resistance or extreme temperature stability.

Manganese, silicon, or aluminium are added during the steelmaking process to remote dissolved oxygen from the melt. Manganese, silicon, nickel, and copper are added to increase strength by forming solid solutions in ferrite. Chromium, vanadium, molybdenum, and tungsten increase strength by forming second-phase carbides. Nickel and copper improve corrosion resistance in small quantities. Molybdenum helps to resist embrittlement. Zirconium, cerium, and calcium increase toughness by controlling the shape of inclusions. Manganese sulfide, lead, bismuth, selenium, and tellurium increase machinability. All mentioned alloying elements can form either compounds or carbides.

* eutectoid – эвтекетоид (сплав, точка плавления которого выше точек плавления входящих в его состав компонентов).

** eutectic – эвтектический (сплав, точка плавления которого ниже).

 

Exercise 3 . Complete the sentences:

1. The term “alloy” determines…

2. The main alloying element in ferrous metals is …

3. The ferrous alloys with less than 2,14 % С are termed as…

4. Ferrous and non-ferrous alloys are widely used in …

5. Aluminium alloys are mainly used because of …

6. Aluminium alloys possess desirable property of …

7. Zink alloys have advantages over…

8. Titanium alloys are applied in …

9. Alloying elements are added to some metals in order to…

10. All alloying elements can form …

 

Exercise 4 . Insert the proper words into the sentences:

1. The term (сплав) determines material (содержащий) more than one element.

2. (Углерод) is the main (легирующий) element in (черный) metals.

3. Each metal (обладать) distinct (свойствами).

4. Steels are alloys of (железо) and (углерод) with other (легирующими) elements.

5. Gray (чугун) is weak and (хрупкий).

6. (Ковкий чугун) possesses high amount of (тягучесть).

7. (Недостатком) of aluminium alloys is their low (температура плавления).

8. Aluminium alloys are used where (требуется легкий вес).

9. (Медные сплавы) form such metals, as (латунь) and (бронза).

10. Titanium is inert in (биологической среде) and is widely used in (медицина).

 

Exercise 5 . Find in the text the sentences that correspond to the following statements:

1. The amount of carbon in metals may differ.

2. Different amount of carbon form quite different alloys.

3. Each metal has its own properties depending on the alloying elements.

4. Different amount of carbon affects the types of steels.

5. Cast irons can be divided into several groups.

6. Aluminium alloys show various useful features.

7. In engineering there is a great variety of non-ferrous alloys.

8. The aluminium alloys can have some other alloying elements and are useful in particular technical conditions.

9. Titanium is used in different fields due to its numerous remarkable properties.

10. Alloying elements in certain proportions improve the properties of metals.

 

Exercise 6 . Translate into English:

1. Термин «сплав» означает материал, состоящий более чем из одного элемента.

2. Основным легирующим элементом черных металлов является углерод.

3. В зависимости от процентного содержания углерода сплавы делятся на стали и чугуны.

4. Существуют не только черные, но и цветные сплавы.

5. Как черные, так и цветные металлы обладают эластичностью, тягучестью, ковкостью и прочностью.

6. Такие металлы, как медь, магний, никель и цинк придают сплавам особые свойства.

7. Титан обладает уникальными качествами и широко применяется в медицине.

8. Титан проявляет высокую устойчивость к коррозии, легкость, прочность на растяжение, но главным является инертность по отношению к биологической среде.

9. Легирующие элементы добавляются к другим металлам, чтобы создать новые, улучшенные свойства материала.

10. Известными легирующими элементами являются силикон, хром, свинец, висмут, селен и теллур.

 

Speaking:

Exercise 7 . Give the summary of the text, using key vocabulary and tell about:

a) the concept of alloy;

b) ferrous and non-ferrous metals and alloys;

c) importance of metals and alloys in engineering;

d) the aim of melting various elements with metals;

e) the properties of alloys;

f) the spheres of application of some metals and alloys.

 

Checklist for Section III:

1. How are compound conjunctions translated into Russian?

2. What is conversion?

3. What are the widely used metals for forming alloys?

4. What properties do metals give the alloys?

Section IV. Steels

Grammar: Gerund.

Word-formation: Suffix -ity.

Speaking: Types and properties of steels.

Practise the reading of the words:

enough	[I′nΛf]
microstructure	[/maIkrə′strΛktòə]
typical	[tIpIkəl]
require	[rI′kwaIə]
pressure	[′preòə]
surgical	[′sə:dჳIkəl]

Learn the pronunciation and meaning of the words:

cost-effective		затратный, расходный
treatment		обработка
austenitize	[/ɔ:stənItaIz]	аустенитизировать (создавать немагнитный твердый раствор углерода)
quench	[kwentò]	закаливать (металл)
temper		закаливать с последующим отпуском
hacksaw blade		ножовочное полотно
plain carbon steel		низкоуглеродистая сталь
alloy steel		легированная сталь
high-strength low alloy steel	высокопрочная низколегированная сталь
pressure vessel		сосуд высокого давления
stainless steel		нержавеющая сталь
cutlery	[′kΛtlərI]	ножевые изделия
susceptibility	[sə/septə′bIlItI]	подверженность, чувствительность, восприимчивость
punch		штамп, пуансон, пробойник
stamping die	[daI]	штамповочная пресс-форма
suitability	[/sju:tə′bIlItI]	пригодность
tap		метчик (для нарезки резьбы)
milling cutter		фреза
tool bit		вставной резец
gear cutter		зуборезная фреза

 

Vocabulary development: word building:

Exercise 1 . Translate the original and derivative words, using a dictionary and create several new words by adding suffixes:

verb	noun (abstract)	noun (personal)	adjective
to improve	improvement	improver	допускающий улуч-шение
to divide	делимость division divisor	divider	dividual divisible divisional
to quench	quencher quenching	-	незакаленный
to temper	temper	-	-
-	susceptibility	-	susceptible восприимчивый
подводить пригождаться	suit suitability	suitor	-

Exercise 2 . Translate the following word combinations with Gerund:

alloying material, alloying metal, quenching, alloying additions, tempering, alloying elements, hardening tool steel, alloying constituent, stamping die, metal cutting tool, cutting edge, tool steels are used for making tools, impact loading, milling cutter.

 

Text

Read the text giving classification and properties of steels:

Steels

Steels are widely known and mostly used materials in comparison with any other ones. Steels are alloys of iron and carbon with other alloying elements. Carbon is the most cost-effective alloying material for iron, but various other alloying elements are used – manganese, chromium, vanadium and tungsten. The latter are necessary to improve many properties of steels – corrosion resistance, strength, formability and others. Mechanical properties of steels greatly depend on carbon content. According to this indication the steels are basically divided into three kinds: low carbon, medium carbon and high carbon.

Carbon is limited in low carbon steels and not enough to strengthen them by heat treatment, but only cold one. The microstructure of low carbon steels consists of ferrite and pearlite, they are relatively soft, ductile and possess high toughness. They are weldable and easily machined. The typical applications of these steels are: structural shapes, tin cans, automobile body components, building, etc.

Medium carbon steels are stronger than low carbon steels, although are less ductile, but their strength can be improved by heat treatment. Usual heat treatment includes austenitizing, quenching and tempering. Such alloying additions as nickel, chrome and molybdenum improve their hardness. The sphere of application of medium carbon steels is railway tracks and wheels, gears, the machine parts which require strength and toughness.

High carbon steels are the strongest and hardest and therefore their ductility is very limited. Their hardness is achieved with addition of such alloying elements as chrome, vanadium, molybdenum and bismuth. These steels possess very high wear resistance and are used for sharp edged tool application: knives, razors, hacksaw blades, etc.

The other parameter for classification of steels is amount of alloying addition. According to this criterion the steels are of two kinds: plain carbon steels and alloy steels. A special group of ferrous alloys with considerable amount of alloying additions is known as HSLA (high-strength low alloy steels). Common alloying elements are copper, vanadium, nickel, bismuth, chrome, molybdenum and others. These alloys are ductile, formable and applied in support columns, bridges, and pressure vessels.

Another widely used kind of steel is stainless steels. They are highly resistant to corrosion and are called rustless or stainless. Highly corrosion resistance is achieved by addition of special alloying elements, especially a minimum of 12 % chrome along with nickel and molybdenum. The typical application of such steels is cutlery, razor blades, surgical tools, etc. Besides, in engineering it is accepted to differ some other kinds of steels: structural steel, carbon steel, alloy steel, tool steel, self (air) hardening tool steel, heat-resisting steel, high speed steel.

Structural steel is widely applied because of its strength, toughness, workability, but it has two drawbacks – heavy weight and susceptibility to rust.

Carbon steel is steel where the main alloying constituent is carbon, and when no minimum content is required for chromium, cobalt, niobium, molybdenum, nickel, titanium, tungsten, vanadium or zirconium. High carbon steel is very strong and used for springs, high-strength wires, knives, axles, punches, stamping dies, metal cutting tools, etc.

Alloy steel is steel alloyed with other elements in amounts of between 1 and 50 % by weight to improve its mechanical properties. These steels have greater strength, hardness, hot hardness, wear resistance, hardenability and toughness compared to carbon steel. However, they require heat treatment in order to achieve such properties. Common alloying elements are molybdenum, manganese, nickel, chromium, vanadium, silicon and boron. Such steels are used where high corrosion resistance in certain environmental conditions is needed.

Tool steel refers to a variety of carbon and alloy steels that are particularly well-suited to be made into tools. Their suitability comes from their hardness, resistance to abrasion, ability to hold a cutting edge and resistance to deformation at elevated temperatures. Tool steels are generally used in a heat-treated state for making tools which have to withstand impact loading.

High speed steel (HSS) is basically iron – carbon alloy in which various elements, principally tungsten and molybdenum, have been added to improve their hardness, toughness, heat resistance and wear resistance. High speed steels are usually used in the manufacture of various cutting tools: drills, taps, milling cutters, tool bits, gear cutters, saw blades, punches and dies. High speed steel tools maintain their edge longer than carbon steel ones.

 

Exercise 3 . Complete the sentences:

1. Mechanical properties of steels depend on…

2. Depending on carbon the steels are divided into…

3. Steels are alloys of…

4. The microstructure of low carbon steels consists of …

5. The applications of low carbon steels are…

6. The strength of medium carbon steels can be improved by …

7. The sphere of application of medium carbon steels is…

8. The hardness of high carbon steels is achieved with…

9. One of the parameters for classification of steels is the amount of…

10. Stainless steels are highly resistant to…

Exercise 4 . Insert the proper words into the sentences:

1. (Углерод) is the most (затратный) (легирующий материал).

2. Alloying elements are necessary (чтобы улучшать) (свойства) of steels.

3. Steels (широко известные) материалы.

4. Carbon steels are (свариваемые) and (легко обрабатываемые на станках).

5. Medium carbon steels (прочнее) than low carbon steels, but (менее ковкие).

6. (Прочность) of high carbon steels (достигается) with addition of some (легирующих металлов).

7. High carbon steels (обладают) very high (износоустойчивостью).

8. The steels are divided into (низко углеродистую) and (легированную).

9. High-strength low alloy steels have (значительное количество) of (легирующих добавок).

10. (Нержавеющая сталь) is widely used for (хирургических инструментов).

 

Exercise 5 . Find in the text the sentences that correspond to the following statements:

1. Carbon is the main constituent affecting the mechanical properties of steel.

2. Depending on carbon content the steels are divided into three types.

3. The main purpose of using alloying elements is to make steels strong and corrosion resistant.

4. The amount of carbon influences the mechanical characteristics of steels.

5. Carbon is the most expensive ingredient comparing with others.

6. The amount of alloying additions is one of the parameters that change the type of steels.

7. In machine building there are various types of steels.

8. Structural steel besides its advantages has also some drawbacks.

9. Alloy steel possesses higher characteristics and is used in the most difficult environmental conditions.

10. A lot of tools which need special strength are made of high speed steel.

 

Exercise 6 . Translate into English:

1. Стали – наиболее используемые материалы в машиностроении.

2. Сталь – это сплав железа и углерода.

3. Легирующими элементами стали являются многие металлы: магний, хром, ванадий, вольфрам, никель, алюминий и другие.

4. Добавки к железу меняют свойства сплавов.

5. Легирующие элементы нужны, чтобы улучшить свойства сталей.

6. Стали должны обладать такими свойствами, как прочность, устойчивость к коррозии, ковкость, обрабатываемость.

7. В технике существуют различные сорта сталей: нержавеющая, инструментальная, теплостойкая, высокопрочная, углеродистая.

8. Свойства стали зависят как от количества углерода, так и от количества добавочных элементов.

9. Одни стали должны выдерживать высокие температуры, другие – высокое давление.

10. Для различных строительных сооружений, инструментов и деталей машин используются соответствующие сорта сталей.

 

Speaking:

Exercise 7 . Give the summary of the text, using key vocabulary and tell about:

a) what is steel;

b) the role of carbon in steels;

c) the necessary properties of steels;

d) the necessity of using alloying elements;

e) metals serving as alloying materials;

f) the kinds of steels;

g) the sphere of application of steels.

 

Checklist for Section IV:

1. What are the functions of Gerund and its difference from Participle I?

2. What is the meaning of the suffix - ity?

3. What properties should steels possess?

4. What are the types of steels and where are they applied?

Text

Read the text describing various means of metal fabrication:

Fabrication of metals

Metals are fabricated by different means to achieve metals and alloys of desired characteristics. Metal fabrication techniques are mainly of four kinds: casting, forming, machining and joining.

Casting is the process of giving a shape by pouring in liquid metal into a mold that holds the required shape, and letting harden the metal without external pressure. This technique is employed when a product is of large and/or complicated shape and when material is of low ductility. There are different casting techniques: sand, die, investment, continuous casting. In common casting methods sand is used as casting material. This method consists in a two-piece mold (cope and drag) formed by compact packing of sand around a pattern of required shape.

In die casting metal is forced into mold by external pressure at high velocities. Here usually a permanent two-piece mold made of steel is used. In this technique rapid cooling rates are achieved.

By investment casting the pattern (mold) is made of wax. Then fluid slurry of casting material is poured over which eventually hardens and holds the required shape. This technique is employed when high dimensional accuracy of fine details is required, for example, jewelry, dental crowns, gas turbine blades, jet engine impellers.

In continuous casting solidification and primary forming process are combined, where refined metal is cast directly into a continuous strand which is cooled by water jets.

Forming is the process of giving shape in solid state by applying pressure. In these techniques, a metallic piece is subjected to external pressures to induce deformation when material acquires a desired shape. Most common forming techniques are: forging, rolling, extrusion and drawing.

Forging involves deforming a single piece of metal by successive blows or continuous squeezing. Forged products have very good mechanical properties and typically include crane hooks, wrenches, crank shafts, connecting rods.

Rolling involves passing a piece of metal between two rotating rolls. Deformation is terms of reduction in thickness resulting from applied compressive forces. This technique is employed to produce sheets, strips, foil, I-beams, rails, etc.

Extrusion is the technique in which a piece of material is forced through a die orifice by a compressive force. Final product will have the desired shape and reduced constant rectangular cross sectional area over very long length. The main extrusion products are: rods, (seamless) tubes, complicated shapes for domestic purpose.

Drawing is pulling material through die orifice using tensile forces. By using drawing technique rods, wire and tubes are commonly produced.

Machining is the process when metal is removed from certain areas of the workpiece to give final required shape to the product. Machining is usually employed to produce shapes with high dimensional tolerance, good surface finish and complex geometry.

Joining is the process where different parts are joined by various means: welding, brazing, soldering and riveting. The first three techniques involve melting metal which upon cooling provides cohesive bonds. In riveting parts are put together by mechanical locking. These techniques are employed to join two pieces of metal with complicated shapes.

Exercise 3 . Complete the sentences:

1. There are four main methods of metal fabrication…

2. In casting metal hardens without…

3. The main casting techniques are …

4. In die casting metal is forced into mold by…

5. In investment casting the mold is made of…

6. Forming metals is realized in solid state by…

7. The most common forming methods are …

8. Forged products have very good…

9. Machining produces goods with high dimensional…

10. In riveting different parts are joined by the following means…

 

Exercise 4 . Insert the proper words into the sentences:

1. (Изготовление металлов) is realized by different methods.

2. (При литье) (жидкий металл) is poured into molds.

3. Casting technique (применяется) in the case of large and (сложных форм).

4. In die casting (внешнее давление) is applied.

5. By investment casting (форма) is made of (воск).

6. (Высокая точность размеров) is required in (лопастях турбин), (пропеллерах реактивных двигателей).

7. By forming the details (подвергаются) (внешнему давлению).

8. One of the forming techniques is (ковка).

9. By drawing process (прутья) and (проволока) are produced.

10. (Механическая обработка) is the process of removing metal (с заготовки).

 

Exercise 5 . Find in the text the sentences that correspond to the following statements:

1. To achieve necessary characteristics of metals four main fabrication methods are used.

2. The most common method is to pour in liquid metal into the mold.

3. There are some varieties of casting technique.

4. As a rule a mold consists of two parts.

5. Metal molds allow quick cooling.

6. When high accuracy of small details is needed the special molds are used.

7. In continuous casting two processes are joined.

8. The materials acquire a designed shape when they are subject to external pressures.

9. Deformation of metal in forging process results in good mechanical features of products.

10. Rolling technique gives the opportunity to fabricate products of small thickness.

 

Exercise 6 . Translate into English:

1. Существуют различные способы обработки металлов и сплавов.

2. Наиболее распространенными способами являются: литье, штамповка, механическая обработка и сборка.

3. Обычно литье осуществляется в формах, где металл затвердевает.

4. Способы литья разнообразны: песочная форма, пресс-форма, по моделям и непрерывная разливка.

5. Как правило, форма состоит из двух частей: верхней части и нижней полуформы.

6. Металлические формы способствуют быстрому охлаждению жидкого металла.

7. Все способы литья дают точные размеры деталей.

8. При штамповке детали придается форма в холодном состоянии.

9. Технология формовки включает ковку, прокатку, выдавливание и протяжку.

10. Сборка – это механическое соединение деталей различной формы путем сварки, пайки и клепки.

 

Speaking:

Exercise 7 . Give the summary of the text, using key vocabulary and tell about:

a) casting metals;

b) types of molds;

c) the difference between forming and forging;

d) opportunities to meet requirements of high dimensional accuracy;

e) various means of joining.

 

Checklist for Section V:

1. How is Participle II is translated into Russian in the function of an attribute?

2. What is the difference of the suffix – er for abstract and personal nouns?

3. What are the main techniques of metal fabrication?

4. What are subdivisions of processes of metal fabrication?

Introduction. Machine Tools

Study vocabulary:

The numerical control (NC) machine – станок с числовым программным управлением, станок с ЧПУ

A paper tape – перфолента

A punch card – перфокарта

Computerized numerical control (CNC) – управление от ЭВМ

A magazine – магазин

A drill bit – сверло

Text: Machine Tools

Read and translate

A machine tool is a powered mechanical device, typically used to fabricate metal components of machines by machining, which is the selective removal of metal. The term machine tool is usually reserved for tools that used a power source other than human movement, but they can be powered by people if appropriately set up. Many historians of technology consider that the true machine tools were born when direct human involvement was removed from the shaping or stamping process of the different kinds of tools. The earliest lathe with direct mechanical control of the cutting tool was a screw-cutting lathe dating to about 1483. This lathe "produced screw threads out of wood and employed a true compound slide rest".

Machine tools can be powered from a variety of sources. Human and animal power are options, as is energy captured through the use of waterwheels. However, machine tools really began to develop after the development of the steam engine, leading to the Industrial Revolution. Today, most are powered by electricity.

Machine tools can be operated manually, or under automatic control. Early ma