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Manufacturing Technology, Vol. 1 Foundry, Forming and Welding

Book · May 2013

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Nageswara Rao Posinasetti

University of Northern Iowa
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 Contents
Preface ix
1. Introduction 1
1.1 Manufacturing Processes  1
1.2 Break-Even Analysis  4
Summary  8
Questions  8
Problems  8
Multiple-Choice Questions  9
Answers to Multiple-Choice Questions  9
2. Engineering Materials 10
2.1 Engineering Properties  10
2.2 Ferrous Materials  19
2.3 Nonferrous Materials  35
2.4 Heat Treatment of Metals  39
Summary  54
Questions  55
Multiple-Choice Questions  57
Answers to Multiple-Choice Questions  58
3. Metal-Casting Processes 59
3.1 Introduction  59
3.2 Patterns  64
3.3 Moulding Materials  81
3.4 Cores  109
Summary  119
Questions  119
Problems  121
Multiple-Choice Questions  123
Answers Multiple-Choice Questions  124
4. Gating Systems for Casting 125
4.1 Introduction  125
4.2 Gating-System Design  136
4.3 Risering Design  149
4.4 Solidification Simulation  164

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 viii Contents

Summary  167
Questions  167
Problems  168
Multiple-Choice Questions  170
Answers to Multiple-Choice Questions  171
5. Melting and Casting Quality 172
5.1 Melting Practices  172
5.2 Casting Cleaning  186
5.3 Casting Defects  187
5.4 Product Design for Sandcastings  190
Summary  202
Questions  202
Problems  204
Multiple-Choice Questions  206
Answers to Multiple-Choice Questions  207
6. Special Casting Processes 208
6.1 Shell Moulding  208
6.2 Precision Investment Casting  211
6.3 Permanent Mould Casting  213
6.4 Die Casting  216
6.5 Vacuum Die Casting  222
6.6 Low-Pressure Die Casting  222
6.7 Centrifugal Casting  223
6.8 Continuous Casting  226
6.9 Squeeze Casting  229
6.10 Slush Casting  230
6.11 Vacuum Casting  230
Summary  231
Questions  232
Multiple-Choice Questions  232
Answers to Multiple-Choice Questions  233
7. Metal-Forming Processes 234
7.1 Nature of Plastic Deformation  234
7.2 Rolling  239
7.3 Forging  253
7.4 Extrusion  279
7.5 Wire Drawing  287
7.6 Rod and Tube Drawing  290
7.7 Swaging  291
7.8 Tube Making  292
7.9 Explosive Forming  293
7.10 Thread Rolling  294
Summary  294
Questions  295

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 Contents ix

Multiple-Choice Questions  298

Answers Multiple-Choice Questions  299
8. Sheet-Metal Operations 300
8.1 Press-Tool Operations  300
8.2 Shearing Action  301
8.3 Shearing Operations  304
8.4 Drawing  310
8.5 Draw Die Design  313
8.6 Spinning  318
8.7 Bending  318
8.8 Stretch Forming  322
8.9 Embossing and Coining  323
8.10 Sheet-Metal Die Design  323
Summary  352
Questions  352
Problems  354
Multiple-Choice Questions  357
Answers to Multiple-Choice Questions  358
9. Welding Processes 359
9.1 Fabrication Methods  359
9.2 Gas Welding  364
9.3 Gas Cutting  370
9.4 Electric Arc Welding  374
9.5 Arc Cutting  411
9.6 Resistance Welding  411
9.7 Welding Design  421
Summary  436
Questions  436
Problems  439
Multiple-Choice Questions  440
Answers to Multiple-Choice Questions  441
10. Other Fabrication Processes 442
10.1 Thermit Welding  442
10.2 Electro-Slag Welding  443
10.3 Electron Beam Welding  444
10.4 Laser-Beam Welding  446
10.5 Forge Welding  447
10.6 Friction Welding  448
10.7 Diffusion Welding  449
10.8 Explosion Welding  450
10.9 Ultrasonic Metal Welding  450
10.10 Brazing  452
10.11 Braze Welding  455
10.12 Soldering  455

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 x Contents

Summary  457
Questions  457
Multiple-Choice Questions  458
Answers to Multiple-Choice Questions  459
11. Powder Metallurgy 460
11.1 Introduction  460
11.2 Production of Metallic Powder  461
11.3 Processing Methods  464
11.4 Advantages and Limitations  470
11.5 Other Compaction Methods  471
11.6 Designing For P/M  472
Summary  474
Questions  474
Multiple-Choice Questions  474
Answers to Multiple-Choice Questions  475
12. Plastic Processing 476
12.1 Introduction  476
12.2 Properties of Plastics  477
12.3 Additives in Plastics  478
12.4 Plastic Materials  479
12.5 Extrusion of Plastics  483
12.6 Injection Moulding  486
12.7 Blow Moulding  492
12.8 Thermoforming  496
12.9 Thermosetting Materials  499
12.10 Plastic Product Design  501
Summary  502
Questions  502
Multiple-Choice Questions  503
Answers to Multiple-Choice Questions  503
Appendix 504
Bibliograhy 508
Index 511

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