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 |  موضوع: كتاب A Textbook of Production Technology الخميس 07 أبريل 2022, 4:50 am | |
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أخواني في الله
أحضرت لكم كتاب
A Textbook of Production Technology
(Manufacturing Processes)
Dr. P.C. SHARMA
B.Sc. Engg. (Mech.) (Hons.)
M.Sc. Engg. (Mech.) (Distinction)
Ph.D. (I.I.T. Delhi)
LMISME, MISTE
Ex. Principal, SUSCET,
Tangori (Mohali), Punjab
Formerly from
Punjab Engineering College,
Chandigarh
و المحتوى كما يلي :
CONTENTS
1. INTRODUCTION 1–10
1.1. Introduction 1
1.2. Classification of Manufacturing Processes 1
1.3. Various Kinds of Production 3
1.4. Computers in Manufacturing 3
1.5. Selection of a Manufacturing Process 4
PROBLEMS 10
2. ENGINEERING MATERIALS AND HEAT TREATMENT 11–72
2.1. Engineering Materials 11
2.2. General Material Property Definitions 11
2.3. The Iron - Carbon Phase Diagram 12
2.4. Heat Treatment Definitions 19
2.5. Ferrous Metals 21
2.6. Heat Treatment of Steels 32
2.7. Hardenability 44
2.8. Designation of Steel (Indian Standard) 47
2.9. Non-ferrous Metals and Alloys 49
PROBLEMS 68
3. THE CASTING PROCESS 73–211
3.1. General 73
3.2. Sand -Mould Casting 74
3.3. Patterns 84
3.4. Moulding Materials 93
3.5. Cores 103
3.6. Gates and Risers 111
3.7. Sand Casting Defects 131
3.8. Design of Castings 135
3.9. Miscellaneous Casting Processes 139
3.10. Cleaning and Finishing of Castings 174
3.11. Inspection and Testing of Castings 176
3.12. Repairing and Salvaging Defective Castings 180
3.13. Choice of Casting Method 181
3.14. Comparison of Casting Process with Other Processes 182
3.15. Cupola 182
3.16. Some More Casting Processes 191
3.17. Foundry furnaces 195
3.18. Pouring and Handling equipment 200
PROBLEMS 202
4. MECHANICAL WORKING OF METALS 212–321
4.1. General 212
(v)4.2. Rolling 221
4.3. Forging 235
4.4. Extrusion 265
4.5. Pipe and Tube Manufacturing 272
4.6. Hot Drawing and Cupping 275
4.7. Drawing of Wire, Rod and Tube 278
4.8. Sheet Metal Working or Press Working of Sheet Metals 284
4.9. Hobbing, Riveting and Staking 313
4.10. Shot Peening 313
4.11. Characteristics of Metal Forming Processes 318
PROBLEMS 318
5. THE WELDING PROCESS 322–404
5.1. General 322
5.2. Gas Welding 329
5.3. Electric Arc Welding 339
5.4. Resistance Welding 363
5.5. Miscellaneous Welding Processes 369
5.6. Liquid-Solid-State Bonding 378
5.7. Weldability 384
5.8. Testing and Inspection of Welded Joints 387
5.9. Welding Cost 392
5.10. Design Aspects 394
5.11. Hard Facing of Metals 397
5.12. Characteristics of Welding Processes 398
PROBLEMS 400
6. THE MACHINING PROCESS 405–426
6.1. General 405
6.2. The Mechanics of Chip Formation 405
6.3. Single Point Cutting Tool 405
6.4. Methods of Machining 413
6.5. Types of Chips 413
6.6. Principal Elements of Metal Machining 415
6.7. Thermal aspects of chip formation 419
6.8. Tool Wear and Tool Life 422
6.9. Machineability 424
PROBLEMS 426
7. CUTTING TOOL MATERIALS AND CUTTING FLUIDS 427–444
7.1. General 427
7.2 Cutting Tool Materials 428
7.3. Cutting Fluids 437
PROBLEMS 442
8. MACHINE TOOLS 445–564
8.0. General 445
(vi)8.1. Lathe Machines 449
PROBLEMS 472
8.2. Shapers, Planers and Slotters 473
PROBLEMS 487
8.3. Drilling Machines 487
PROBLEMS 499
8.4. Reaming 499
PROBLEMS 502
8.5. Boring 502
PROBLEMS 508
8.6. Milling 508
PROBLEMS 530
8.7. Grinding Operation 531
PROBLEMS 552
8.8. Broaching Machines 553
PROBLEMS 557
8.9. Sawing Machines 557
PROBLEMS 563
9. UNCONVENTIONAL MANUFACTURING METHODS 565–600
9.1. General 565
9.2. Electrical Discharge Machining (EDM) 568
9.3. Electro-chemical Machining (ECM) 573
9.4. Electrolytic Grinding or
Electro-chemical Grinding (ECG) 576
9.5. Chemical Milling 579
9.6. Ultrasonic Machining (USM) 581
9.7. Use of High Energy Densities for Machining 583
9.8. High Energy Rate Forming (HERF, HVF) 586
9.9. Some other Non-traditional Machining Methods (NTMM) 594
PROBLEMS 598
10. POWDER METALLURGY 601–625
10.1. Introduction 601
10.2. Advantages and Limitations of P/M 601
10.3. Manufacture of Metal Powders 603
10.4. Mixing and Blending 609
10.5. Compacting (Briquetting) 609
10.6. Sintering 614
10.7. Secondary Operations 615
10.8. Recent Trends in Powder Metallurgy 619
10.9. Properties of Powder Metallurgy Parts 621
10.10. Applications of P/M Parts 621
10.11. Designing the P/M Parts for Production 622
10.12. Comparison of Powder Metallurgy with Other Processes 623
PROBLEMS 623
(vii)11. PROCESSING OF PLASTICS 626–649
11.1. General 626
11.2. Polymers 626
11.3. Polymerization 626
11.4. Additions to Polymers 627
11.5. Plastics 628
11.6. Processing of Thermoplastic Plastics 630
11.7. Processing of Thermosetting Plastics 633
11.8. Casting of Plastics 634
11.9. Machining of Plastics 635
11.10. Other Processing Methods for Plastics 636
11.11. Welding of Plastics 638
11.12. Design of Plastic Parts 641
11.13. Basic Principles of Design of Moulds for Plastic Parts 644
PROBLEMS 648
12. SPECIAL PROCESSING METHODS 650–674
12.1. Hot Machining 650
12.2. Unit Heads 651
12.3. Plastic Tooling 652
12.4. Electro - Forming 653
12.5. Surface Cleaning and Surface Treatments 655
12.6. Adhesive Bonds 666
12.7. Surface Coatings for Tooling 669
12.8. Fine Blanking 671
12.9. Counter-blanking 672
12.10. Nosing 673
PROBLEMS 673
13. CERAMIC MATERIALS AND THEIR PROCESSING 675–687
13.1. General 675
13.2. Classification of Ceramics 675
13.3. Properties of Ceramics 676
13.4. Processing of Ceramics 677
13.5. Product Applications 679
13.6. Enamels 681
13.7. Glass 681
13.8. Design Considerations of Ceramic Products 686
PROBLEMS 687
14. COMPOSITE MATERIALS AND THEIR PROCESSING 688–702
14.1. General 688
14.2. Types of Composite Materials 688
14.3. Production of Composite Structures 696
14.4. Machining, Cutting and Joining of Composites 700
PROBLEMS 701
15. TRACER CONTROLLED MACHINE TOOLS 703–712
15.1. General 703
(viii)15.2. Mechanical Copying Machines 704
15.3. Hydraulic Tracing Devices 706
15.4. Electric Tracing Systems 711
15.5. Automatic Tracing 712
PROBLEMS 712
16. NUMERICALLY CONTROLLED MACHINE TOOLS 713–726
16.1. General 713
16.2. Working of NC Machine Tools 714
16.3. Classification of NC Machines 716
16.4. Programming for NC Machines 718
16.5. Methods of Listing the Co-ordinates of Points in NC System 720
16.6. Applications of NC Machines 720
16.7. Advantages and Disadvantages of NC Machines 721
16.8. Computer Numerical Control (CNC) and Direct Numerical Control (DNC) 722
16.9. Machining Centre 724
16.10. Adaptive Control 725
PROBLEMS 725
17. SURFACE FINISHING PROCESSES 727–739
17.1 Introduction 727
17.2 Surface Finishing Processes 729
17.2.1. Diamond Turning and Boring 729
17.2.2. Grinding 729
17.2.3. Lapping 730
17.2.4. Honing 732
17.2.5. Buffing 734
17.2.6. Barrel Tumbling 734
17.2.7. Barrel Rolling 735
17.2.8. Super Finishing 736
17.2.9. Burnishing 736
17.2.10. Powder Coating 737
17.2.11. Polishing 738
PROBLEMS 739
APPENDIX–I 740–745
APPENDIX–II : Machining Variables and Related Relations 746–758
APPENDIX–III 759–810
Problems from Competitive Examinations & Question Papers (GATE, IES, IAS)
APPENDIX–IV: Additional Material 811–827
INDEX 828–833
NDEX
828
A
Abrasives, 531
– Coated, 546
Abrasive Machining 551
Abrasive Jet Machining, AJM, 594
Additives, 95
Adhesive Bonds, 666
Aging, 21
Agglomerated materials, 689
Aluminium and its alloys, 50
Anti-friction alloys, 58
Anisotropy, 11
Annealing, 20
Angle of Repose, 82
Austenitic Steel, 29
B
Barrel Tumbling 734
Barrel rolling 735
Bars and Gaggers, 80
Babbit Metals, 59
Bainite, 35
Bell metal, 56
Bending, 304
Binders, 94
Bonding materials, 533
Boring, 502
Boring Machines, 502
Boring Mills, 469
Boring Tools 507
Brass, 54
Brazing, 379
– Methods, 381
– Filler Metals, 380
Brittleness, 11
Broaching Machines, 553
– Types of, 554
– Drive, 556
– Size of, 556
– Advantages, 557
– Limitations, 557
Bronze, 55
– Phosphor, 56
– Silicon, 56
– Manganese, 56
– Aluminium, 56
– Beryllium, 57
Buffing 734
Burnishing 736
C
Case Hardening, 20, 38
Cast Iron, 21
– Alloy, 23
– Chilled, 23
– Ductile, 23
– Effect of alloying elements on, 24
– Gray, 21
– Heat treatment of, 25
– Malleable, 22
– Meehanite, 24
– White, 22
Casting Process, 73, 820
– Advantages, 73
– Applications, 73
– Classification of, 74
– General, 73
Cast Steels, 32
Casting Yield, 820
Cemented Carbides, 68
Centreless grinding, 541
Ceramic Mould casting, 172
Centrifugal Casting, 163
Centrifuge Casting, 165
Ceramic material and their processing, 675
Chaplets, 110
Cheek, 81
Chemical Milling, CHM, 579
Chemical Vapour Deposition, CVD, 670
Choice of Casting Methods, 181
Cleaning and Finishing of Castings, 174
Classification of Manufacturing Processes, 1
Coining, 312
CIP 613Index 829
Cold Shortness, 12
Cold Welding, 180
Cold Working, 12, 214
Composite materials and their processing, 688
Computers in Manufacturing, 3
Continuous Casting, 173
Continuous extrusion, 270
Copper and its alloys, 54
Cores, 103
– Finishing and Coating of, 109
– Types of, 109
Core Baking, 105
Core-box, 104
Core Dryer, 105
Core Manufacture, 104
Counter Blanking, 672
Critical Points, 13
Cutting Fluids, 437, 820, 821
Cutting Tool Materials, 427
– Plain Carbon Steel, 428
– Alloy Tool Steels, 429
– H.S.S. 429
– Non Ferrous Cast alloys, 431
– Cemented Carbides, 432
– Ceramics, 435
– Cermets, 435
– Diamonds, 436
– Cubic Boron Nitride, 436
– UCON, 436
– Sialon, 437
– Coronite 437
Cutting Die, 291, 293
Cupola, 182
Cyaniding, 20, 42
Cylindrical grinding, 539
D
Damping Capacity, 12
Deep Drawing, 301
Deep Hole Drilling, 497
Design of Castings, 135
Designation of Steel, 47
Designation of Cutting Tools, 407
– ASA, 407
– ORS, 411
Diffusion Annealing, 33
Diffusion Coatings, 671
Diffusion Welding, 374
Dividing Heads, 521
– Types of, 521
Die–Casting, 139
– Product Applications, 140
– Limitations of, 141
– Machines, 141
– Hot Chamber, 143
– Cold Chamber, 144
– Design of, 146
– Design of Dies for, 148
– Die Materials, 152
– Recent Trends in, 156
Directional Solidification, 117
Drilling Machines, 487, 491
Drilling Tools, 488
– Core drills, 490
Ductility, 11
Dynapak Machine 593
E
EBW, 375
Eff-set method, 192
Elasticity, 11
Elastic Recovery, 284
Electric Arc Welding, 339
– Power Sources, 340
– Electrodes, 343
– Types of, 348
– Carbon, Arc, 349
– SMAW, 349
– FCAW, 352
– GTAW (TIG), 352
– GMAW (MIG), 353
– MAG, 355
– SAW, 356
– Atomic Hydrogen, 357
– ESW, 357830 A Textbook of Production Technology
– EGW, 358
– PAW, 358
– Stud, 359
Electric Arc Cutting, 361
Electron Beam Machining, 583
Electro-Chemical Deburring, 579
Electro-Chemical Honing, 578
Electro-Chemical Grinding, 576
Electro-Chemical Machining, 573
Electro-Discharge Grinding, 572
Electro-Discharge Machining, 568
– Wire Cut, 571
– PMEDM, 600
Electro-Forming, 653
Electro-magnetic Casting, 194
Electrolytic Polishing, 658
Embossing, 312
Embrittlement, 12
Enamels, 681
Engineering Materials, 11
Extrusion, 265
– Hot, 265
– Direct, 265
– Indirect, 266
– Ratio, 267
– Machines for, 267
– Cold, 267
– Continuous, 270
– Side, 270
– Advantages of, 269
– Helical 271
– Explosive 272
– Drawbacks of, 269
Explosive Welding, 373
F
Ferritic Steel, 31
Fine Blanking, 671
Filament Winding 698
Flame Hardening, 21, 39
Flaskless Moulding process, 193
Flow-off, 125
Flow Turning, 311
Flow Welding, 373
Forging, 235
– Basic Operations, 237
– Processes, 238
– Hammers, 238
– Open Die, 241
– Closed Die, 242
– Drop, 243
– Press, 245
– Machine (Upset), 248
– Roll, 251
– Rotary, 252
– Trimming and Straightening of, 252
– Defects in, 254
– Cleaning and finishing of, 255
– Metallurgy of, 256
– Heat Treatment of, 256
– Cold, 258
– New Trends in, 259
Forgeability, 253
Forge Welding, 369
Friction Welding, 370
Full annealing, 20
Full Mould Casting, 172
Foundry furnaces 195
G
Gates, 115, 126
Gating System, 112
Gatorizing, 263
German Silver, 62
Graphite Mould Casting, 191
Glass, 681
Grain growth, 128
Grinding, 53
Greeep-feed, 815
Grinding Machines, 539
Grinding Ratio, 539
Grinding Wheels, 534
– Dressing and Truing of, 538
Gun Metal, 56Index 831
H
Hardness, 12
Hard facing of Metals, 397
Hardening and Tempering of Steels, 34
Hand Moulding Process, 78
Hastealloy, 63
Heat Treatment of Steels, 32
Helical extrusion, 271
Hydrogen embrittlement, 12
High Energy Rate Forming, HERF, 586
– Explosive Forming, 586
– Electro-Hydraulic Forming, 589
– Electro-Magnetic Forming, 590
High Velocity Forming, HVF, 591
– Petro-forging, 592
– Dynapak, 593
Hot Die forging, 260
Hot drawing and Cupping, 275
Hobbing, 313
Homogeneity, 11
Honing 732
Hot Isostatic Pressing, HIP, 264, 619
Hot Machining, 650
Hot Working 12, 217
Hydro-Mechanical forming, 308
Hydrostatic Wire extrusion, 281
High Speed Grinding 551
I
Inconel, 62
Incoloy, 62
Induction Hardening, 21
Induction Welding, 369
Incremental Forging, 264
Invar, 62
Ion Beam Machining, IBM, 597
Inspection and Testing of Castings, 176
Ion Plantation, 671
Iron-Carbon Phase Diagram, 12
Isothermal Annealing, 33
Isothermal Forging, 260
Isotropy, 11
J
Jig Borer, 506
Jiggering, 678
K
Kevlar, 702
Killed Steel, 32
K–Monel, 62
Kyon 444
L
Lapping 730
Laminates, 698
Laser Beam Machining, 584
Laser Beam Welding, 376
Lathe Machines, 449
– Engine Lathe, 450
– Lathe Operations, 449
– Turret Lathes, 467
– Tracer Lathes, 468
– Vertical Turret Lathes, 468
– High Production Lathes, 469
– Gap lathe, 469
Lederburitic Steel, 29
Liquid forging, 262
Liquid-Solid State bonding, 378
Lost Wax Method, 166
M
Machineability, 12, 424
Machine Moulding, 81
Machining Process, 405
Machine Tools, 445
– Classification of, 445, 821
Magnesium and its alloys, 53
Malleability, 12
Martensite, 19, 35
Martensitic Steel, 31
MAPP gas welding, 337
Measurement of temperature in cutting Zone
420
Mercast Process, 170
Mechanical working of metals, 212
– Advantages, 212832 A Textbook of Production Technology
– Classification, 214
Mechanics of Chip Formation, 405
Metal Spinning, 309
Metallization, 180
Metal Injection Moulding, 621
Methods of Indexing, 522
– Direct, 522
– Simple, 522
– Compound, 523
– Differential, 524
Monel Metal, 62
Moulding Sand, Properties 98
Moulding Materials, 93
Mould Surface Coatings, 96
Milling, 508
– of Helical grooves, 815
– Cam, 817
– Thread, 818
Milling Machines, 509
– Types of, 510
Milling Cutters, 513
– Types of, 513
Milling Operations, 518
N
Nickle and its alloys, 60
Nickle Maraging Steels 72
Nichrome, 62
Nimonics, 62
Normalising, 20
Nitriding, 21, 41
Nosing, 673
Nucleation, 128
Numerically controlled machine tools 713
O
Oblique Cutting, 413
Orthogonal Cutting, 413
Orbital Forging, 263
Oxy-acetylene flame cutting, 338
P
Patterns, 84
– Materials, 85
– Finishing of, 87
– Allowances, 87
– Types of, 89
– Colour Scheme for, 92
Physical Vapour Deposition, PVD, 671
Permanent Mould Casting, 157
Pearlitic Steel, 128
Petro-Forging, 592
Pig Iron, 21
Pilgering process, 277
Pipe and Tube Manufacture, 272
Planers, 481
– Principal parts of, 481
– Types of, 483
– Size of, 484
– Drive, 484
Planing and Shaping Tools, 485
Plaster Mould Casting, 171
Plasticity, 11
Plasma Arc Machining, 585
Plastic Tooling, 652
Pouring Basin, 114
Polishing, 738
Powder Forging, 261
Powder Metallurgy, 601
– Basic Steps of, 601
– Advantages and limitations, 601
– Metal Powders, 603
– Metal Powder Characteristics, 606
– Pre-alloyed and Pre-coated powders, 608
– Mixing and Blending, 609
– Compacting, 609
– Sintering, 614
– Presintering, 615
– Secondary Operations, 615
– Recent trends in, 619
– Properties of P/M parts, 621
– Applications of P/M Parts 621
– Design of P/M parts, 622
Pouring and Handling Equipment 200
Precision Investment Casting, 166
Presses, 286
Press Operations, 284
Press Selection, 290
Press Brake, 306Index 833
Press Working Dies, 291
– Cutting, 291, 293
– Forming, 294
– Simple, 294
– Compound, 294
– Combination, 294
– Progressive, 295
– Transfer, 295
– Multiple, 295
Principal elements of metal machining, 415
Pressure gas welding, PGW, 337
Process annealing, 20, 33
Processing of Plastics, 626, 821
– Polymers, 626
– Polymerisation, 626
– Additives to Polymers, 627
– Plastics, 628
– Types of Plastics, 628
– Properties of Plastics, 629
– Injection Moulding, 630
– Extrusion, 631
– Sheet Forming Process, 632
– Compression Moulding, 633
– Transfer Moulding, 633
– Casting of Plastics, 634
– Machining of Plastics, 635
– Calendering, 636
– Rotational Moulding, 637
– Blow Moulding, 637
– RIM, 637
– Welding, 638
– Design of Plastic parts, 641
Powder Coating 737
Pultrusion, 698
Q
Quenching, 20
R
Radial Drilling Machine, 495
Reaming, 499
Red Shortness, 12
Redrawing, 302
Refractories, 679
Refractory Metals, 63
Resistance Welding, 363
– RSW, 363
– RSEW, 366
– RPW, 366
– Butt, 367
– Upset Welding, 367
– Flash Butt, 368
– Percussion Butt, 368
Repairing of Castings, 179
Rimmed Steel, 33
Risers, 116
Riveting, 313
Rod drawing, 278
Roll forming, 274, 307
Rolling, 221
– Mechanism of, 223
– Mills, 224
– Ring, 230
– Cold, 231
Rolling Millcontrol 231
Rolling defects 232
RTM, 697
Rubber-Hydroform Process, 308
Rubber-Press forming, 307
Runners, 114
S
Sand, 93
– Types of, 93
– Properties of, 98
– Testing of, 100
Sand Casting Defects, 131
Sand Mould Casting, 74
– Types of, 75
– Comparison of, 77
Sawing Machines, 557
Semi-Centrifugal Casting, 165
Semi-Killed Steel, 32
Selection of a manufacturing process, 4
Semi-Steel, 32
Sheet metal working, 284
Shell Moulding, 168
Shot Peening, 313
Shapers, 473
– Types of, 473834 A Textbook of Production Technology
– Horizontal, 474
– Drive of, 476
– Size, 479
– Advantages of, 479
– Vertical, 479
Side extrusion, 270
Single point cutting tool, 405
Soldering, 383
Soldiers, 81
Sorbite, 35
Slotters, 480
– Types of, 480
– Size of, 480
– Drive of, 480
Slush Casting, 161
Snap flask moulding process, 193
Special Grinding Machines, 544
Spheroidizing, 34
Sprue, 114
Sprue base, 114
Stack Moulding, 93
Staking, 313
Steels, 26
Stiffness, 12
Stellite, 64
Stress relieving, 20
Stretch forming, 309
Super-Plastic Forging, 264
Surface Coatings, 669
Surface Cleaning and Surface Treatment, 655
Surface Grinding, 544
Super Finishing, 733
T
Tandem Wire Drawing, 281
Tempering, 44
Testing and Inspection of Welded Joints, 387
Thermal Aspects of Chip Formation, 419
Thermit Welding, 376
Titanium alloys, 63
Toughness, 12
Tool Life, 422
Tool Wear, 422
Tool Designation, 411
Troostite, 35
Tube Drawing, 282
Tube Manufacture, 272
Tracer Controlled Machine Tools, 703–712
Types of Chips, 413
U
Ultra-Sonic Cleaning, 657
Ultra-Sonic Machining, 581
Ultra-Sonic Welding, 372
Unit Heads, 651
Unconventional Machining Methods, 565–600
– Classification of, 566
– Process Selection, 566
– Limitations of, 567
V
Vacuum Casting of Metals, 192
Vacuum moulding process, 191
Vacuum Shielded Welding of Metals, 360
Vertical Shapers, 479
Vittalium, 63
W
Warm Forging, 260
Water Jet Machining, 596
Welding Cost, 392
Welding Defects, 387
Weldability, 384
Welding Metallurgy, 389
Welding Process, 322
– Applications, 322
– Advantages, 322
– Classification, 323
– Types of Weld Joints, 324
– Types of Welds, 325
– Edge Preparation, 325
– Welding Positions, 327
– Cleaning the Joint and Fluxing, 328
– Gas Welding, 329
– Electric Arc, 339
– Design aspects,394
Welding of Plastics, 638
Wire Drawing, 279
Wrought Iron, 25
Z
Zinc and its Alloys
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