기계공작법 이해 - 대학 과정 이론과 실제

이학재 (지은이)일진사

2023-03-20

공작기계의 이론을 개략적으로 이해하고 원리를 터득하여 실제 기구, 부품의 가공기술과 연계하여 산업현장의 실무에 적용할 수 있도록 하였다. 활용도가 높은 공작기계는 각론에서 선삭, 연삭, 형삭 등에 관한 이론 및 특성, 가공방법과 같은 실무적응에 필요한 내용을 이해하기 쉽게 수록하였고, 품질관리를 위한 측정 관련 이론 및 특성, 사용방법 등을 함께 기술하였다.

목차

제1편 주 조

제1장 모형

1. 모형용 재료 ························ 16

1-1 목재의 장점 ······································· 16

1-2 목재의 단점 ······································· 16

2. 목형용 목재 ························ 17

2-1 목재의 조직 및 수축 ························· 18

2-2 목재의 기계적 성질 ·························· 19

2-3 목재의 건조 ······································· 20

2-4 목재의 방부법 ··································· 22

2-5 목재의 선택 방법 ······························ 23

3. 목형용 보조 재료 ··················· 23

3-1 접착제와 결합제 ································ 23

3-2 도장 재료 ·········································· 24

4. 목형 제작 방법 ····················· 25

4-1 현도법 ················································ 25

4-2 목형 제작상의 유의 사항 ·················· 25

4-3 목형의 종류 ······································· 28

5. 목형 공작용 수공구 및 기계 ·········· 31

5-1 목형용 수공구 ··································· 31

5-2 목형용 기계 ······································· 34

6. 목형의 조립방법 ···················· 39

6-1 목재의 접착 ······································· 39

6-2 못나사 접착 ······································· 40

6-3 주먹 장부 맞춤과 잔형 ····················· 40

6-4 다월 맞춤 ·········································· 40

제2장 주조

1. 주물의 개요 ······················· 42

1-1 주물의 특징 ······································· 42

2. 모래 주형 재료 ····················· 43

2-1 모래 주형 재료 ································· 43

3. 주물사의 종류 ····················· 45

3-1 생형사 ················································ 45

3-2 건조사 ················································ 46

3-3 코어사 ················································ 46

3-4 분리사 ················································ 46

3-5 표면사 ················································ 47

3-6 도형재 ················································ 47

4. 주물사의 재생 처리법 ··············· 47

4-1 주물사의 노화현상 ···························· 47

4-2 주물사의 재생처리 ···························· 49

5. 주물사 처리용 기계 ················· 50

5-1 분쇄기 ················································ 50

5-2 혼사기 ················································ 51

5-3 자기 분리기 ······································· 51

5-4 투사기 ················································ 51

6. 주물사 시험법 ······················ 51

6-1 강도 시험법 ······································· 52

7. 주형용 공구 및 시설 ················ 56

7-1 주형용 공구 ······································· 56

7-2 주형용 수공구 ··································· 57

7-3 주형용 기계 ······································· 57

8. 주형 제작법 ······················· 59

8-1 주형 재료에 의한 분류 ····················· 60

8-2 주형법에 의한 분류 ·························· 60

9. 주조 방안 ························· 61

9-1 탕구계의 구성 ··································· 62

9-2 주입온도 및 주입시간 ······················· 65

9-3 압상력 ················································ 67

10. 주물 후처리 ······················ 68

10-1 주물의 해체 ····································· 68

10-2 주물의 청소 ····································· 68

11. 특수 주조법 ······················· 68

11-1 원심 주조법 ····································· 69

11-2 다이캐스팅 ······································· 69

11-3 셸 몰드법 ········································ 70

11-4 인베스트먼트법 ································ 71

11-5 연속 주조법 ····································· 72

11-6 이산화탄소법 ··································· 73

12. 주물의 결함과 검사법 ··············· 74

12-1 주물의 결함과 방지 방법 ················ 74

12-2 주물의 검사 ····································· 76

제3장 용해와 용해로

1. 용해로의 개요 ······················ 79

2. 용해로의 종류 ····················· 80

2-1 도가니로 ············································ 80

2-2 전로 ··················································· 81

2-3 평로 ··················································· 81

2-4 반사로 ················································ 82

2-5 전기로 ················································ 83

2-6 용선로 ················································ 85

제4장 주물용 금속재료

1. 주철의 개요 ······················· 88

2. 주철의 분류 ······················· 89

2-1 회주철 ················································ 89

2-2 고급 주철 ·········································· 89

2-3 구상 흑연주철 ··································· 91

2-4 가단주철 ············································ 91

2-5 합금 주철 ·········································· 93

2-6 냉경주물 ············································ 94

3. 주강 ····························· 94

3-1 보통주강 ············································ 95

3-2 합금주강(특수 주강) ·························· 95

4. 구리 합금 ························· 96

4-1 황동 ··················································· 96

4-2 청동 ··················································· 97

5. 알루미늄 합금 ····················· 97

6. 마그네슘 합금 ····················· 99

제2편 소성가공

제1장 소성가공의 개론

1. 소성가공의 개요 ··················· 102

1-1 소성변형 ·········································· 102

1-2 소성가공에 이용되는 재료의 성질 ·· 102

1-3 응력과 변형률 ································· 103

1-4 재결정 ············································· 104

1-5 열간가공과 냉간가공 ······················· 105

1-6 냉간가공 ·········································· 106

2. 소성가공의 종류 ··················· 108

제2장 단조

1. 단조의 개요 ······················· 110

2. 재료 가열법 ······················· 111

2-1 단조 온도 ········································ 111

2-2 가열로 ············································· 113

2-3 온도 측정 ········································ 114

3. 단조용 재료 ······················· 115

3-1 단련강 ············································· 115

3-2 탄소강 ············································· 115

3-3 특수강 ············································· 116

3-4 구리 합금 ········································ 116

3-5 경합금 ············································· 116

4. 단조용 공구 및 기계 ················ 117

4-1 단조용 공구 ····································· 117

4-2 단조 기계 ········································ 118

5. 단조작업 ························· 123

5-1 자유단조 ·········································· 123

5-2 형단조 ············································· 125

제3장 압연

1. 압연의 개요 ······················· 128

2. 압연 작용 ························ 129

2-1 압하율 ············································· 129

2-2 폭 증가 ············································ 129

2-3 접촉각 ············································· 130

3. 압연기의 종류 ····················· 130

4. 롤러 ···························· 133

4-1 롤러의 구조 ····································· 133

4-2 롤러의 재질 ····································· 134

5. 특수 압연기 ······················ 134

5-1 맨네스맨 압연기 ······························ 135

5-2 유니버설 압연기 ······························ 135

5-3 플러그 압연기 ································· 136

5-4 로터리 압연기 ································· 136

5-5 릴링 압연기 ····································· 136

6. 압연 작업 ························ 137

6-1 분괴압연 ·········································· 137

6-2 후판압연 ·········································· 139

6-3 형강 압연 ········································ 139

제4장 인발가공

1. 인발의 개요 ······················· 140

2. 인발의 분류 ······················ 140

2-1 봉재 인발 ········································ 140

2-2 관재 인발 ········································ 140

2-3 선재 인발 ········································ 141

2-4 롤러 다이법 ····································· 141

2-5 디프 드로잉 ····································· 142

3. 인발 조건 ························ 143

3-1 단면 감소율 ····································· 143

3-2 역장력 ············································· 143

3-3 인발속도 ·········································· 144

3-4 다이 각 ············································ 144

3-5 인발에서의 윤활 ······························ 145

4. 인발용 기계 ······················ 146

4-1 신선기 ············································· 146

4-2 인발기 ············································· 146

4-3 교정기 ············································· 147

제5장 압출

1. 압출의 개요 ······················· 148

2. 압출 방법 ························ 148

3. 압출기와 공구 ····················· 150

4. 압출압력과 윤활 ··················· 151

제6장 제관

1. 제관의 개요 ······················· 153

제7장 프레스 가공

1. 프레스 가공의 개요 ················· 155

2. 프레스 가공의 분류 ················ 155

3. 프레스 가공용 재료 ················ 156

3-1 철 금속 ············································ 156

3-2 구리 및 구리 합금 ·························· 156

3-3 알루미늄 및 알루미늄 합금 ············ 157

4. 프레스 가공용 기계 ················ 157

4-1 프레스의 분류 ································· 157

4-2 인력 프레스 ····································· 158

4-3 동력 프레스 ····································· 159

5. 전단가공 ························· 164

5-1 전단작용 및 전단각 ························ 164

5-2 전단가공 ·········································· 166

6. 굽힘가공 ························· 169

6-1 굽힘 변형 ········································ 169

6-2 최소 굽힘 반지름 ···························· 170

6-3 스프링 백 ········································ 171

6-4 굽힘 작업 ········································ 172

7. 드로잉 가공 ······················· 175

7-1 펀치의 곡률 반지름 ························ 175

7-2 다이의 곡률 반지름 ························ 176

7-3 펀치와 다이의 간격 ························ 176

7-4 드로잉 작업 ····································· 177

제3편 용 접

제1장 용접 개론

1. 용접의 개요 ······················ 180

1-1 용접의 원리 ····································· 180

1-2 용접법의 종류 ································· 180

1-3 용접법의 특징 ································· 182

2. 용접이음의 종류 ··················· 182

2-1 모재의 배치에 따른 종류 ················ 182

2-2 맞대기 용접 ····································· 183

2-3 필릿 용접 ········································ 183

2-4 플러그 용접 ····································· 184

2-5 덧살올림 용접 ································· 184

3. 용접 기호 ························ 184

3-1 용접부의 기호 ································· 184

3-2 용접부의 기호 표시방법 ················· 186

3-3 보조 기호 등의 기재방법 ················ 187

제2장 피복아크 용접

1. 피복아크 용접의 원리 ··············· 189

1-1 아크 용접 회로 ······························· 190

1-2 아크의 특성 ····································· 190

1-3 정전류 특성 ····································· 190

2. 용접기의 특성 ····················· 191

2-1 수하 특성 ········································ 191

2-2 정전압 특성, 상승특성 ··················· 191

2-3 극성 ················································· 191

2-4 자기쏠림 ·········································· 192

2-5 아크길이 ·········································· 192

2-6 용접입열 ·········································· 193

2-7 용융속도 ·········································· 193

2-8 용착 현상 ········································ 193

3. 아크용접 기기 ····················· 194

3-1 피복아크 용접기기 ·························· 194

4. 피복아크 용접봉 ··················· 197

4-1 피복제의 역할 ································· 197

4-2 피복 용접봉의 종류 ························ 198

4-3 용접봉 표시기호 ······························ 199

4-4 용접봉의 보관 ································· 199

4-5 용접 ················································· 200

5. 아크용접 결함의 종류 및 방지대책 ···· 202

5-1 용접 결함의 종류 ···························· 202

5-2 용접부의 결함과 방지대책 ·············· 202

...