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Loading...Production Technology
K. L. Narayana
Former Principal
Prof, Department of Mechanical Engineering
Sri Venkateswara University College of Engineering
Tirupatht – 517 502
Swarna Venkata Ramana
Associate Professor
Department of Mechanical Engineering
Gmr Institute of Technology
Rajam – 532 127
P. Vamsi Krishna
Assistant Professor
Department of Mechanical Engineering
Gttam College of Engineering
Visakhapatnam – 530 045
Contents
Fundamentals of Metal Casting
Lijmmducdon3.
Lu What is a Casting? /
12 Moulding Materials 2
1.2.1 General Composition of Moulding Sand 2
1.2.2 Types of Moulding Sand 4
1.2.3 Moulding Sand Properties 5
1.3 Classification of Metal Cast!ng Processes 6
\ a Steps Involved in Making a Casting 8
125 Advantages of Casting / /
1.5. 1 Applications I I
L6 Cores and Coremaking /2
Ij Types of Foundry /5
L7»l Foundry Layout 16
1.7.2 Some_of the Considerations in a Foundry Shop Layout 77
Patterns and Patternmaking 17
1.8.1 Types of Patterns 17
L82__ Malejiials. Used Tor .j7u.lte.ms_2d
1.8.3 Pattern Allowances 2.l
L9 Review Questions 25
L1q Objective Questions 26
I. 1-29
1 ,8
2. Moulding and Casting Processes
2.1 Fntraduction 50
22
_ Shelly Moulding 30
23 Cq
? Moulding 33
2.4_ Centrifugal Casting 34
24j _ True Centrifugal Casting 34
2.4.2 Semi Centrifugal Casting 34
24_3 Centrifuging 36
25 Die Casting Process_37
General Procedure of Die Casting 37
233.__tiat_chamb£ii_pj:ocess37.
7.5 3 Cold Chamber Process J_8
2.6 Investment Casting 39
23 Review Questions 41
2.8 Objective Questions 42
30-44
2.5. Jviii Contents
3, Furnaces Solidification of Castings and Casting Defects 45*57
3.1 Introduction 45.
3.2 Melting Furnaces 45
3.2.1 Crucible Melting 46
3.2.2 Cupola and Its Operation 47
33 So I Idification of Casting 50
33.1 Solidification of Pure Metal 50
33.2 Nucleaf Ion and Growth 51
33.3 Shrinkage 51
33.4 Types of Solidification 51
3.4 Defects in Castings 52
35 Review Questions 55
3.6 Objective Questions 55
4. Gating and Kisering of Castings
4.1 Introduction 58
42 Principles of Gating System 58
4.2.1 Gating System 59
43 Design of Gating System 63
43.1 Pouring Time 63
43.2 Proportions of Other Gating Elements 65
4a Riser Functions and Riser Types 67
4.4.1 Types of Riser 67
45 Riser Design 68
45.1 Riser Shape 68
Casting Design Considerations 70
4.6. 1 Casting Design and Cost Reduction 72
4.7 Review Questions 72
43 Objective Questions 73
5. Fundamentals of Welding
5.1 Introduction 79
5.2 History and Development of Welding 79
5.2. 1 Basie Requirements 81
53 Classification of Welding Processes 81
5a Types of Welds 81
5.4. 1 Types of Weld Joints S3
5.4.2 Weld Design 84
55 Review Questions 84
5.6 Objective Questions 85
6. Welding Processes
6.1 Introduction 86
62 Are Welding 86
6.2.1 Mode of Metal Transfer 87
6.2.2 Arc Welding Electrodes 88
6.23 V-i Characteristics of Welding Power Source 90
58-78
4.6
79-85
86-136contents R.v
62.4 Magnetic Arc Blow 93
63 Shielded Metal Arc Welding (Smaw) 94
6a Submerged Arc Welding (Saw) 96
63 Tungsten Inert Gas Welding (Tig) 97
6.6 Metal Inert Gas Welding (Mig ) 99
6.7 Gas Welding Ioo
6.7. 1 Oxy-acetylene Flame 707
6.7.2 Types of Oxy-acetylene Flame 101
6.7.3 Oxy-acetylene Welding Equipment 103
67.4 Filler Rod 104
675 Fluxes 105
63.6 Gas Welding Techniques 705
67.7 Gas Welding Procedure 106
63 Resistance Welding 107
6.8. 1 Spot Welding 70s
6.8.2 Seam Welding 7/7
6.8.3 Projection Welding 112
6.9 Solid State Welding 114
6.9. 1 Forge Welding 114
6.9.2 Friction Welding 115
6 ,93 Explosive Welding 7 / 7
6.10 Thermit Welding /20
6j 1 Radiant Energy Welding 727
6.1 1.1. Laser Welding 121
6.12 Induction Welding 123
6.13 Soldering 123
634 Brazing 725
635 Heat Affected Zone 126
636 Review Questions 727
6.17 Objective Questions 130
7. Defects, Testing and Economics of Welding
73 Introduction 137
12 Weld Defects 137
7.23 Insufficient Fusion 137
7.2.2 Inadequate Penetration 137
7.2.3 Over Penetration or Under Cutting 137
7.2.4 Slag Inclusions 138
7.2.5 Porosity 138
7.2.6 Cracking 138
7.2.7 Corrosion 739
73 Testing of Weldments 739
733 Visual Inspection 139
7.3.2 Liquid Penetrant Inspection 139
7.3.3 Magnetic Particle Inspection 140
137-150jt Contents
7.3.4 Ultrasonic Inspection 141
7.3.5 Radiography 141
7.4 Economics of Welding J 42
7.4. 1 Welding Costs 143
7.4.2 Standard Time 144
15 Review Questions 148
7.6 Objective Questions /49
8. Metal Working
84 Introduction 151
8+2 Metal Working Processes 15 /
8.24 Classification of Forming Processes /52
83 Strain Hardening 154
8.3. 1 Annealing 154
8.3.2 Comparison of Hot and Cold Working 156
8.4 Roiling Fundamentals 157
8.4.1 Hot Rolling and Cold Rolling 157
8.4.2 Theory of Rolling 157
83 Analysis of Rolling 160
8.54 Determination of Rolling Pressure 160
8.5.2 Determination of Neutral Section /62
8.5.3 Role of Front and Back Tensions on Rolling Load /62
8.5.4 Determination of the Roll Separating Force 163
8.5.5 Determination of Torque and Power 163
8.5.6 Reduction of Rolling Forces 164
8.6 Types of Roiling Mill 164
8.64 Two High Non-reversing Mills 164
8.6.2 Two High Reversing Mills / 64
8.6.3 Three High Rolling Mills 165
8.6.4 Four High Rolling Mills 165
8.6.5 Cluster Rolling Mills /66
8.6.6 Planetary Rolling Mill /66
8
R7 Rolling Products 166
8.8 Review Questions 168
8.9 Objective Questions 169
9. Extrusion and Forging
94 Introduction / 74
9.2 Basic Extrusion Process / 74
9.24 Characteristics of Extrusion / 75
9.3 Hot Extrusion 176
9.3. 1 Forward Extrusion 176
9.3.2 Backward Extrusion 176
9.4 Cold Extrusion / 77
9.4. 1 Forward Extrusion / 77
9.4.2 Backward Cold Extrusion 178
151-173
174-204contents Xt
9.5 Rod Drawing Iso
9.5. 1 Wire Drawing 181
9.5.2 Tube Drawing 181
9.5.3 Determination of Force and Power in Wire Drawing 182
9.5.4 Maximum Possible Reduction in Wire Drawing 184
9.6 Determination of Force in Extrusion 185
9.7 Forging 187
9.7.1 Open Die Forging 187
9.7.2 Closed Die Forging or Drop Forging 188
9.7.3 Press Forging 189
9.7.4 Upset or Machine Forging 190
9.7.5 Roll Forging 190
9.7.6 Orbital Forging 191
9.8 Forging Muehines 191
9.8. 1 Forging Presses 191
9.8.2 Hammers 196
9.9 Determination of Force in Forging Operation 197
9.10 Review Questions 200
9.1 J Objective Questions 207
10, Sheet Metal Working
104 Introduction 20,5
10,2 Press Operations 206
10.2. 1 Shearing Operation 206
103 Working of a Cutting Die 208
1034 Types of Dies 209
10.4 Forming Operations 213
10.4.1 Drawing 2 / 3
10.4.2 Bending Process 216
10.43 Spinning 218
10.4.4 Embossing 220
10.4.5 Stretch Forming 220
10.4.6 Swaging 221
10.4.7 Coining 222
10.5 Types of Presses 222
10.6 Review Questions 222
10.7 Objective Questions 223
11, Plastics
11.1 Introduction 227
I 1.2 Plastics 227
L 1.2. 1 Molecular Structure of the Plastics 228
11.2.2 Polymerization 228
I I 3 Types of Plastics 229
11.34 Thermoplastics 229
11.3.2 Properties and Applications of Thermoplastics 229
205-226
227-236xii Contents
11.3.3 Thermosetting Plasties 23!
11.3.4 Properties and Applications of Thermosetting Plasties 231
1 1.4 Processing of Plastics: Methods and Equipment 232
11.4. 1 Moulding Processes 232
11.4.2 Injection Moulding 232
11.4.3 Blow Moulding 235
References 237-238
Index 239-242
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