PRODUCTION TECHNOLOGY VOL. I

160.00

By K. G. ASWANI

1st Edition 2007
336 + 16 = 352 Pages
Size : 17 cm × 24 cm × 1.5 cm
Weight : 0.465 kg

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Description

The book on “Production Technology” is prepared in two Volumes. The Vol. I contains
“Manufacturing Processes and Materials”, where as Vol. II is separately published which
contains “Machine Tools and Metal Removal Processes”
The entire subject matter is presented in simple and lucid language. Number of figures, graphs,
tables and solved examples are contributed along with the text matter to understand the subject
matter easily.
The book contains 12 Chapters and Appendix:
* 187 Neatly drawn self-explanatory diagrams
* 77 Useful Tables giving technical data
* 28 Solved Examples
* 159 Questions and Exercises are given at the end of chapters.
It is the fervent hope of the author that this book will satisfy the needs of the Mechanical,
Production, Automobile Engineering students preparing for the B.Tech/B.E. examinations
of almost all the Indian Universities, Diploma examinations conducted by various Boards of
Technical Education, Certificate courses as well as for the A.M.I.E., U.P.S.C., G.A.T.E. and other
similar competitive and professional Examinations. It should also be of an immense help to the
practising Mechanical Engineers.

Additional information

Weight 0.465 kg
Dimensions 17 × 1.5 × 24 cm
Author Name

Book Edition

ISBN

,

Content

1 : MANUFACTURING TECHNOLOGY
2 : MANUFACTURING MATERIALS
3 : PROPERTIES AND TESTING OF MATERIALS
4 : PLASTIC FLOW AND MECHANICAL WORKING OF
METALS
5 : ROLLING AND EXTRUSION
6 : FORGING
7 : SHEET METAL FORMING
8 : SAND MOULDING PRACTICES AND METAL CASTING
9 : MELTING FURNACES
10 : WELDING AND OTHER JOINING PROCESSES
11 : PLASTICS AND PLASTIC MOULDING
12 : SURFACE FINISHING AND COATINGS
Appendix : useful tables
Index
About the book

Details Content

    >Chapter 1 MANUFACTURING TECHNOLOGY

    1-1 Introduction
    1-2 Design considerations
    1-3 Factors affecting manufacturing processes
    1-4 Types of materials
    1-5 Manufacturing processes
    1-6 Manufacturing cost
    1-7 Break even point
    1-8 Reasons for cost estimates
    1-9 Factors affecting estimates
    1-10 Skills required for cost estimates
    Exercise 1

    Chapter 2 manufacturing materials

    Part I: Ferrous metals
    2-1 Introduction
    2-2 Types of cast iron
    2-3 Iron–carbon equilibrium diagram
    2-4 Types of carbon steels
    2-5 Effect of residual elements on carbon steels
    2-6 Alloy steels–classification
    2-7 Alloying elements
    2-8 Properties of stainless steels and alloy steels
    2-9 Material coding (designation) system
    Part II: Non-ferrous metals and alloys
    2-10 Aluminium and aluminium alloys
    2-11 Copper and copper alloys
    2-12 Magnesium and magnesium alloys
    2-13 Titanium alloys
    2-14 Zinc and zinc alloys
    2-15 Tin and tin alloys
    2-16 Bearing alloys
    Part III: Ceramics
    2-17 Ceramics–constituents, structure and properties
    2-18 Ceramic fibres
    2-19 Ceramic composites
    Part IV: Composites
    2-20 Composites
    2-21 Materials for nuclear energy
    Exercise 2

    Chapter 3 PROPERTIES AND TESTING OF MATERIALS

    3-1 Properties of materials
    3-2 Elastic and plastic behaviour
    3-3 Stress and strain
    3-4 Stress–strain diagram for carbon steel
    3-5 Yield and tensile strength
    3-6 Compressive, shear and torsional strengths
    3-7 Ductility
    3-8 Malleability
    3-9 Brittleness
    3-10 Hardness
    3-11 Hardenability
    3-12 Toughness
    3-13 Stiffness
    3-14 Tenacity
    3-15 Resilience
    3-16 Factors affecting mechanical properties
    3-17 Impact strength
    3-18 Hardness tests
    3-19 Fracture
    3-20 Factors affecting fracture

    3-21 Fracture failure prevention
    3-22 Fracture toughness
    3-23 Factors affecting fracture toughness
    3-24 Fatigue
    3-25 Factors affecting fatigue properties
    3-26 Fatigue test
    3-27 Creep
    3-28 Factors affecting creep
    3-29 Mechanism of creep
    3-30 Creep resisting materials
    3-31 Non destructive testing (NDT)
    3-32 X-rays properties and applications
    Exercise 3

    Chapter 4 Plastic flow and mechanical working
    of metals

    4-1 Introduction
    4-2 Variables in metal working
    4-3 Wrought versus cast metals
    4-4 Plastic deformation
    4-5 Mechanical working processes
    4-6 Cold working
    4-7 Warm working of metals
    4-8 Hot working of metals
    4-9 Work (strain) hardening
    4-10 Annealing of cold worked metals
    4-11 Recovery (stress relieving)
    4-12 Re-crystallisation
    4-13 Grain growth
    4-14 Grain size measurement
    Questions 4

    Chapter 5 Rolling and extrusion

    Part I: Rolling
    5-1 Introduction
    5-2 Principles of rolling
    5-3 Methods of rolling
    5-4 Classification of rolling mills
    5-5 Roll passes
    5-6 Break down passes
    5-7 Draught
    5-8 Roll Materials
    5-9 Tube (roll) piercing
    5-10 Defects in rolled products
    Part II: Extrusions
    5-11 Principle of extrusion
    5-12 Design considerations and limitations
    5-13 Types of extrusions
    5-14 Forward hot extrusion
    5-15 Backward hot extrusion
    5-16 Hydrostatic (forward cold) extrusion
    5-17 Impact (backward cold) extrusion
    5-18 Cold extrusion forging
    5-19 Advantages of extrusion
    5-20 Extrusion blow moulding
    5-21 Extrusion pressure
    5-22 Wire drawing
    5-23 Tube drawing
    5-24 Bar drawing
    5-25 Rotary swaging
    5-26 Straightening
    Exercise 5

    Chapter 6 forging

    6-1 Introduction
    6-2 Drop forging impressions
    6-3 Methods of forging
    6-4 Forging processes
    6-5 Smith forging
    6-6 Drop (die) forging
    6-7 Press forging
    6-8 Machine (upset) forging
    6-9 High energy rate forging
    6-10 Roll forging
    6-11 Forge welding
    6-12 Forging materials
    6-13 Dies for drop forging
    6-14 Dies for upset forging
    6-15 Forging design
    6-16 Design guidelines for dies and punches
    6-17 Allowances on forgings
    6-18 Forging defects
    6-19 General considerations
    6-20 Operations before and after forging
    6-21 Forged vis-à-vis cast parts
    Questions 6

    Chapter 7 sheet metal forming

    7-1 Sheet metal forming processes
    7-2 Shearing operations
    7-3 Shearing with dies
    7-4 Angular clearance for dies
    7-5 Clearances for punch and die
    7-6 Minimum diameter for piercing
    7-7 Design requirements for punch press parts
    7-8 Shearing force and work done
    7-9 Stripping force
    7-10 Drawing
    7-11 Deep drawing
    7-12 Blank size
    7-13 Punch (drawing) force
    7-14 Lubrication
    7-15 Punch (drawing) speed
    7-16 Forming (bending)
    7-17 Forming (bending) methods
    7-18 Bend length
    7-19 Bending load
    7-20 Work done during bending
    7-21 Power required
    7-22 Stretch forming
    7-23 Bulging
    7-24 Coining, embossing and stamping
    7-25 Tests on sheet metals
    7-26 Spinning
    7-27 Power press construction
    7-28 Types of power presses
    7-29 Safety devices for power press
    Exercise 7

    Chapter 8 sand moulding practices and metal
    casting

    Part I: Sand moulding and moulding processes
    8-1 Introduction
    8-2 Basic steps in sand moulding
    8-3 Sand mould preparation

    8-4 Pattern materials and types
    8-5 Pattern allowances
    8-6 Moulding processes and materials
    8-6-1 Processes based upon type of sand used
    8-6-2 Processes based upon machine used
    8-6-3 Special moulding processes
    8-6-4 Methods used
    8-7 Types of moulding sand
    8-8 Properties of moulding sand
    8-9 Sand tests
    8-10 Mould and core materials
    8-11 Core making
    8-12 Core boxes and core plates
    8-13 Core dryers
    8-14 Chaplets
    8-15 Core prints
    8-16 Core sands and binders
    8-17 Core making machines
    8-18 Gating system
    8-18-1 Components of gating system
    8-18-2 Types of gating
    8-19 Gating design
    8-20 Pouring time
    8-21 Fluidity of molten metal and fluidity test
    8-22 Terminology
    Part II: Metal casting
    8-23 Solidification of metals
    8-24 Design for sound castings
    8-25 Types of casting processes
    8-26 Permanent mould castings
    8-27 Expandable mould and pattern castings
    8-27-1 Investment or precision castings
    8-27-2 Plaster mould casting
    8-27-3 Ceramic mould castings
    8-27-4 Antioch casting
    8-28 Permanent pattern casting
    8-29 Newly developed casting process
    Part III: Cleaning and inspection of castings
    8-30 Cleaning and finishing of castings
    8-31 Casting defects and remedies
    8-32 Precautions to avoid defects
    8-33 Inspection of castings
    8-34 Casting yield
    Exercise 8

    Chapter 9 melting furnaces

    9-1 Melting furnaces
    9-2 Types of furnaces
    9-3 Cupola: Melting furnace for ferrous metals
    9-4 Cupola operation
    9-5 Cupola charging
    9-6 Cupola efficiency and heat balance
    9-7 Gas and/or liquid fuel furnaces
    9-8 Open hearth (reverberatory) furnace
    9-9 Air furnace
    9-10 Crucible furnace: For melting non-ferrous metals
    9-11 Non-crucible furnaces
    9-12 Rotary melting furnaces
    9-13 Bessemer converter
    9-14 Ladles
    9-15 Electric furnaces
    9-16 Temperature measurement
    Exercise 9

    Chapter 10 welding and other joining processes

    10-1 Joining processes
    10-2 Welding process
    10-3 Types of welding processes
    10-4 Oxy-acetylene gas welding
    10-5 Gas welding techniques
    10-6 Arc welding
    10-7 Shielded metal arc welding (SMAW)
    10-8 Flux cored arc welding (FCAW)
    10-9 Submerged arc welding (SAW)
    10-10 Gas metal arc welding (GMAW)
    10-11 Tungsten inert-gas (TIG) welding
    10-12 Plasma arc welding (PAW)
    10-13 Resistance welding
    10-14 Solid state welding
    10-15 Thermit welding
    10-16 Electron beam welding (EBW)
    10-17 Laser beam welding (LBW)
    10-18 Electro-slag welding (ESW)
    10-19 Atomic hydrogen welding (AHW)
    10-20 Robotic arc welding (RAW)
    10-21 Types of weld joints
    10-22 Electrode classification
    10-23 Soldering
    10-24 Brazing
    10-25 Braze welding
    10-26 Metallizing
    10-27 Welding of various metals
    10-28 Welding defects
    10-29 Thermal cutting
    10-30 Mechanical fasteners
    10-31 Adhesive bonding
    10-32 Types of adhesives
    10-33 Terminology
    Exercise 10

    Chapter 11 PLASTICS AND PLASTIC MOULDING

    11-1 Introduction
    11-2 Characteristics of plastics
    11-3 Thermoplastic polymers
    11-4 Thermosetting polymers
    11-5 Additives
    11-6 Moulding processes
    11-7 Compression moulding

    11-8 Transfer moulding
    11-9 Injection moulding
    11-10 Design requirements for injection moulding
    11-11 Jet blowing
    11-12 Plastic extrusion process
    11-13 Blow moulding
    11-14 Rotational moulding
    11-15 Calendering
    11-16 Thermo-forming (vacuum forming)
    11-17 Blown film process
    11-18 Casting
    11-19 Design of plastic moulds
    11-20 Machining of plastics
    11-21 Laminates
    11-22 Foamed plastics
    11-23 Summary of plastic moulding processes
    11-24 Joining of plastics
    11-25 Plastics in packaging
    Exercise 11

    Chapter 12 surface finishing and coatings

    12-1 Introduction
    12-2 Cleaning and finishing
    12-3 Chemical cleaning
    12-4 Mechanical cleaning
    12-5 Thermal–explosive debarring
    12-6 Electro-polishing/forming
    12-7 Surface coating
    12-8 Properties of coatings
    12-9 Types of coatings
    12-10 Metallic coatings
    12-11 Organic coatings
    12-11-1 Constituents and application of paints
    12-12 Inorganic coatings
    12-13 Chemical conversions
    12-14 Plastic coating
    12-15 Electron beam coating
    Exercise 12
    Appendix USEFUL TABLES
    Table A–1 S.I. Units, Conversion factors, Prefix names
    Table A–2 Conversion factors
    Table A–3 Prefix names, Symbols and Multiplication factors
    Table A–4 Applicable Indian Standards

    index

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