دانلود کتاب The Repair of Vehicle Bodies

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Cover
Title
Copyright
Dedication
Contents
Preface
1 Car body construction
Starting out
Vehicle safety testing
Elements of vehicle construction
Vehicle information code plate
Brief history of the motor vehicle
Skills and questions
2 Health and safety and the environment
Personal health and safety procedures
Fire precautions
Fire risks in the workshop
Safety signs in the workshop
General safety precautions in the workshop
Electrical hazards
COSHH
RIDDOR
Maintain the health, safety and security of the work environment
Where identified hazards cannot be removed, appropriate action is taken immediately to minimize risk to own and others’ health and safety
Skills and questions
3 Hand and power tools
Hand tools used in body repair work
Hammers
Hand dollies
Body spoons
Body files
Hand snips
Specialist panel beating tools
Clamps
Punches
Edge setters or jogglers
Sheet metal bench stakes
Hand grooving tools
Rivet sets
Cutting tools
Bending and swaging tools
General-purpose assembly and dismantling tools
Skills and questions
4 Materials used in vehicle bodies
Skills
Aluminium
Rubber
Sealers
Sound-deadening, thermal insulating and undersealing materials
Interior furnishings
Plastics
Amorphous and crystalline plastics
Abbreviations for automotive plastics
Types of plastics
Repair procedures
Painting plastics
Safety glass
Skills and questions
5 Metal forming processes
Properties of metals
Heat treatment of steel and aluminium
Machines for sheet metal fabrication
Cutting machines
Bending theory
Bending machines
Rolling machines
Forming and drawing
Sheet metal cutting for press work
Skills and questions
6 Marking out and measuring
Marking out
Manufacture of templates
Basic marking-out and measuring instruments
Precision marking-out and measuring instruments
Micrometer
Skills and questions
7 Methods of joining
Solid rivets
Types of riveted joint
Blind rivets
Repetition rivets
Rivet selection
Structural fasteners
Screws and bolts
Fastening devices
Adhesives
Selection of adhesives
Achieving good results with adhesives
Adhesives and the automotive industry
Skills and questions
8 Soft and hard soldering methods
Comparison of fusion and non-fusion jointing processes
Soft and hard solders
Soft soldering
Hard soldering
Body leading/body soldering
Health and safety and the environment
Skills and questions
9 Gas welding, cutting and plasma arc
Overview of gas welding
Oxy-acetylene welding equipment
Regulators
Definitions of welding terms
Welding rods and fluxes
Flame control and types of flame
Methods of welding
Edge preparation and types of joint
Welding technique: butt joint in mild steel
Welding various metals
Gas cutting
Gases: characteristics and colour coding
Safety measures
Plasma arc cutting
Skills and questions
10 Electric resistive welding
Resistance welding in car body manufacture
Resistance spot welding
Resistance projection welding
Resistance seam welding
Resistance flash welding
Resistance butt welding
Resistance welding in body repair work
Resistance spot welding of high-strength steels
Weld quality
ARO Spotrite Pulsa resistance welding system
Single-sided spot welding
Skills and questions
11 Manual metal arc welding (MMA)
Principles of manual metal arc welding
Electrical terms used in arc welding
Metal arc welding equipment
Electrodes used in welding: BS coding
Arc welding positions
Essential factors of arc welding
Technique of welding
Safety precautions for the welder
Skills and questions
12 Gas shielded arc welding (MIG, MAG and TIG)
Development of gas shielded arc welding
Gases used for shielded arc processes
TIG welding
Application of TIG welding
MIG/MAG welding
MIG/MAG spot/plug welding
Equipment used in MIG/MAG welding
MIG/MAG welding techniques
Applications of MIG/MAG welding in vehicle body construction
Applications of MIG/MAG welding in body repair work
MIG/MAG welding of low-carbon steel and HSLA steels
Welding stress and distortion in the MIG/MAG process
Weld testing and inspection
Equipment maintenance and safety
Skills and questions
13 Craft techniques and minor accident damage
Panel beating: forming panels by hand
Shaping metal by hand
General guide to the fabrication of hand-made panels
Edge stiffening of sheet metal
Techniques of damage rectification
Hammering techniques
Filing
Sanding or disc grinding
Hot shrinking
Cold shrinking
Body soldering
Chemically hardening fillers (plastic fillers)
Body jack (hydraulic)
Application of the body jack
Repair of component motor body panels
Aluminium panel repair
Body electrical and electronic systems
SAE J1930
Skills and questions
14 Major accident damage repair
Damage classification and assessment
Pulling, alignment and repair systems used on major accident damage
Alignment of the modern integral body
Major repair techniques
Skills and questions
15 Bodyshop planning
Initial planning
Planning the areas of the workshop
Bodyshop heating
Bodyshop lighting
Essential equipment for the bodyshop
Bodyshops and legal requirements
Skills and questions
16 Reinforced composite materials
Introduction
Basic principles of reinforced composite materials
Manufacture of reinforced composite materials
Types of reinforcing material
Resins used in reinforced composite materials
Moulding techniques for reinforced composite laminates
Repair of reinforced composite bodies
Common faults in moulded laminates
Safety precautions
Skills and questions
17 Automotive finishing and re-finishing
Glossary of terms used in spray painting
Basic composition of paint
Types of paint
Materials used in refinishing
Spray painting equipment
Types of spray gun
Basic parts of a standard spray gun
Spray gun maintenance and cleaning
Spray gun motion study
Spraying defects
Sanding and polishing machines
Preparation of a motor vehicle for repainting
Finishing and refinishing processes
Burnishing, polishing and final detail work
Rust-proofing
Movement of vehicle in the paint shop
Common spray painting defects
Colour mixing and matching
Vehicle cleaning – detailing
Virtual-reality spraying
Skills and questions
18 Case study
General appearance
Site selection
Pre-planning
Notable points
19 Mechanical, electrical and trim – MET
Science
Impact and momentum
Batteries
Repair pods
Quick reference guide to vehicle systems
Steering and suspension
Skills and questions
Appendix 1: Health and safety risk assessment and COSHH data sheets
Glossary
Index