DESIGN DATA Compiled by Faculty of Mechanical Engineering PSG College of Technology Coimbatore 641 004Sn eee ma First Edition 1968 ‘Second Revised Edition 1971 Third Revised Edition 1978 Reprinted 1979 Reprinted 1980 Copies cais be had from Mis. DPV PRINTERS Kalaikathir Buildings, Coimbatore-641 037 Price Rs. 50/ Printed at DPV Printers Kalaikathir Buildings, Coimbatore-641 037PREFACE Design of an engioeering product is made with the intention of ultimately manufacturing it economically, Modern production engineering places great emphasis on the completeness and clarity of information contained in the engineering drawings and on the maximum use of standard components in the design, Sufficient attention, Jn the design stage, on details regarding attainable eometric, position and dimensional tolerances, the selection of proper materials and process of heat treatment and designing components with minimum machining involved, is often found to result in substantial reduction in the cost of production. It is with this objective, the present revised third edition of the Design Data Book hhas been brought out. One will find in this compilation useful data both on the design as well as production aspects We are highly indebted to the large number of engineers from industries who, after using our Data Books, have made valuable suggestions to update the book in the present form. We are also thankful to many Universities in India for approving this Data Book for use in their Despite our best efforts, should some mistakes have crept in, these may kindly be brought to our notice We welcome constructive criticism for further improve- ‘ment of this compilation, ‘We hope that this revised and enlarged edition will continve to be well recsived by the students of engincering and the designers & shop engineers in industries, Faculty of Mechanical Engineering PSG COLLEGE OF TECHNOLOGY Gxt 30, 1978 Coimbatore - 641 004CONTENTS I: MATERIALS Physical properties, metals 1. 8, Designation of ste! & Al Mechanite Castings, properties CL. Casting, properties & uses Spheroidal graphite & grey icon Castings, properties High tensile cast steel, Carbon steel casting, properties heat resistant steel castings Carbon steel, composition & properties Carbon steel, typical uses Carbon steel, properties Structical see, strength Alloy steel, composition & properties Free cutting steel, composition & properties Al Alloy stel, properties Tool stcel, hardness Tool steel composition Tool steel uses Steels, IS and their equivalents Brasses, Bronze: Composition & properties Bearing alloys, Composition Bearing slloys uses & pouring temp Die casting steel, Composition & uses Aluminium, Composition Aluminium alloys, Characteristics & uses Cast Al alloys, Composition & properties Cast Al alloys, Characteristics & uses Hardness number related to tensile strength Gear materials Plastics, propertie: Endurance limits of metals 2: HEAT TREATMENT Tron Carbon Equilibrium disgram Structural consiwents of Iron-Carbon alloys Choice of Annealing Treatments TTT diagram & Hardenability Curves, EN 8 & C40 EN 9 & C55 EN 24 & 40 Ni2 Cr 1 Mo 28 Salt mixtures, composition and heating time Annealing & hot working temp, metals Hardening & tempering of carbon & alloy steels Colour-coding of heated steel, during tempering Hardness vs % Carbon, Gear hardening Surface hardness thro" induction hardening, grinding allowance & Case depth for gears Heat Treatment—applicato Progressive induction tempering Solid carburisers, liquid nitriding, Niteding Salts Heat Treatment—Aluminium alloys ‘Stees relieving temp, copper alloys, defects in heat treatment3: FITS AND TOLERANCE Machining and surface roughness symbols 3.1 CObtainable surface roughness 3.2 Letter symbol & IT grades of tolerances 3.3 Running & Sliding fits 3.4 Location, transition & Interference fits 35 Recommended machining processes for grades of holes 3.6 Tolerance Table—shaft 3.7 —holes 39 Mean and variation of fits 3:10 Geometric tolerances 3.11 j —do— symbols 312 4: ROLLING ELEMENT BEARINGS Types of Bearings 4.1 Bearing calculations—Ball & Roller 42 Needle 43 Equivalent bearing load 44 Bearing life—recommended 45 t Nomogram, C/P, Ball bearing 46 \ —do— Roller bearing 47 Selection of fit on shafts 48 i —do— on housing 49 ‘Tolerance on inner race, Radial bearing 4.10 Tolerance on outer race U1 Deep groove ball bearings, 60 Series 4.12 Flat cages 437 4 Bearing proportions 4.38STANDARDS & STANDARD COMPONENTS Centre holes 5. Threaded Centre holes 5.2 Girclip, External, type A 53 + Internal, ype B 5.7 «External, type CS. ylindcical pin 5.12 Solid and split taper pin 5.14 Threaded taper pin $.15 Parallel key 53.16 Tangential key 5.18 Gib head key 5.19 Taper key 5.21 Woodruff key $23 Keys for machine tools 5.24 Retaining & Jacking screws for key 5.25 Rivet proportions 5.26 Straight sided splines 5,30 » for mic tools $33 TInvolute sided spines 5.36 Self Holding taper shanks external 5.39, imernal $40 external with tang 5.41 Threads for bolts & nuts $42 Pipe threads 5.43 Bolt & serew ends 5.44 Thead runout & undercut, external 5.45 internal 3.46 Bolts, screws, nuts & locknuts $47 Countersunk screws 5.51 Square head bolts & nuts 5.54 Slotted grub screws 5.37 Hex. Socket grub screw 559 Socket head cap screw 5.61 Studs 5.66 Interference fit, thread 5.6 ISO metric screw, tolerance 5.67 trapezoidal thread 5.68 Square thread 5.69 Slotted mut 5.75 Castle mut S.77 Cap mut 5.81 domed cap nut 5.82 Pitch—diam combination for 180 metric screw 5.83 Ring nus 5.85 Locking washer 5.86 T slots, T nuts 587 T slotted tables 5.88 Washers 5.89 Relief grooves 590 Swing clamp, end locating plug 3.91 Round and diamond locating pin $92 Round and diamond locating stud 5:93 Strap clamp, C washer 5.94 Set collars 5.95 Vee Locator, Dovetail proportions. $.97Jig—Button, feet, nut = feet button. locating pin ig bushes Kourled, Plain & tommy nuts Handle grip screw and wing screw Pressure pad a erews for pressure pad, lock dog Cam lever Spherical washer and conical seat Wb ise Ball grip, Cap, lever rod Equaliser clamp, turning head il seals © rings LL type spindle nose Al _ Cam lock és 7124 taper for Draw bolt end 7/24 taper for tool shanks Foot mounted motor Flange mounted motor Rolled steel, angles > Lsection Channel Tee 598 599 5.100 s.102 5.108, 104 10s 106 108 5.109 5.110 s.it4 S116 sat Sune s.121 sum 5.123 5.126 suas 527 5.129 S31 su32 6: MECHANICS Properties of sections Curved beam Cantilever beam Simply supported beam Fined beam Propped beam Columes Vibration, linear torsional Critical speed Forced vibration with damping Natural frequency constants of beams Thick cylinders Rotating discs of twist and shear stress for sections Bending of circular plate Bending of noncitcular plate Bending of © “Thermal stress in plates, buckling of plates: & tubes angular plate ams on elastic supports Membrane stresses Location of shear centre Static. stresses Failure theories Varying stresses Allowable stress, variable load 61 62 6a 65 66 a 63 69 61 612 63 64 61s 620 6a 624 625 626 62 628 629 632 MACHINE ELEMENTS‘Stress concentration factors 7.8 Contact stress 7.18 Preferred numbers 7.19 Shaft 721 for shaft design (twisting) 7.23, . ; (ending) 7.24 Clindsical shaft ends 7.25 Short tapered shaft ends 7.26 Lubricants, properties 7.28 Journal bearing material selection 7.30 Hydrodynamic journal bearing 7.31 Hydrostatic bearing 7.42 Fluid power symbols 747 Hydrotatic air bearings 748 Flat belts 7:52 Flat belt pulley 7.54 Vee belts 7.88 Vee grooved pulley Roller chain drive 7.71 Chain wheel rim 7.29 Geneva mechanism 781 Ratchet and Pawl 7.85 Power screws 7.87 Clutch, multiple plate 7.89 Unidirectional clutch 7.93 Safety clutch 7.95 Claw clutch 7.96 Brakes 7.97 Coil springs 7.100 Leaf spring 7.108 Spring steel, properties 7.105 Flange couplings 7.106 Cams 7.110 Polydyne came 7.111 Forces on cams 7.116 Displacement and acceleration expressions 7.118. Coupling, design 7.120 Fly wheel 7.121 Connecting rod 7.123 Crankshaft 7.124 Riveted joint 7.125 Bolted joint 7.128 Shoe Brake 7.129 Torsion Spring 7.131 Spiral Spring 7.132 GEARS Gear Nomenclature 8.1 Basic rack 82 Peripheral speed, backlash & standard gear ratios #3 Gear material, selection 8.4 Design stresses, gear 8.5 selection of number of teeth on gears for standard ratios 86 Gear Design formulae & tables 8.13 Gear geomery 822 Gear correction: Charts 8.23, : formulae 824 Specific siding & Contact ratio 8.26Inyolute functions Nomogram: Selection of module & face width of spur gears Tolerance on centre distance Gear inspection data re (straight & spiral) WORM GEAR Lewis & Buckingham equations for spur for helical Bevel & worm SKEW Gears Gear forces Reduction Gear boxes Proportions of large gears Non circular gears BEVEL GEAR, nomencla 828 332 833 834 8.38 843 8.50 8st 852 855 856 858 3a 8.64 9: MATERIALS HANDLING Wire ropes & drums Hoisting gear Proportions, drum groove, sprocket for chain ‘Standard sheave grooves Point hooks ‘Trolley & EOT crane Speeds for EOT eranes Brakes for cranes Belt Conveyor . Bucket elevator Serew conveyor Pneumatic conveyor 91 99 9.10 oat 9.12 9.14 ous 918 904 9.26 10: CASTING ‘Test requirements of Grey Iron castings Properties of unalloyed cast iron based on equivalent carbon Pattera, materials & shrinkage allowance Draft angle and general tolerance on castings Machining allowance, colouring & marking of patterns ction of casting Selection of casting process Moulding sand, properties Cores, permanent moulds Selection of meting furnace Cupola operation Casting defects & remedies Wall thickness and maximam length of casting Casting design, proportions Rules in casting design Minimum A: WEL Weld symbols Stress formulae Weld design—data Weld treated as a line ‘Ege preparation Choice of process 10.4 102 103 104 10s 106 107 108 109 10.10 0.1 10.12 10.14 10.15 10.16 DING ua 3 14 us 1 nsrT 1. S. classification of covered electrodes 'AWS classification of, Selection of MIG Welding TIG Welding Gas welding Gas cutting Gas welding, ferrous metals Spot welding us 11,10 rer nas 1116 it nis a9 1120 12: MACHINING Formulae for power and cutting forces Standard spindle speeds for m/e tools Standard feeds Single point tool geometry Tool angles, HSS 9 carbide Carbide tool classification Spoods and feds, turning . planing trepanning : + boring Tool life, nomograms Drill geometry Speeds and feeds, drilling Speods, reaming Machine tapping Dies for threading Geometry, milling cutter Speods in milling , in broaching Speeds, hacksaw cutting ané bandsaw cutting Designation of grinding wheels Speeds and feeds, cyl. grinding ‘Too! grinding Speeds and feeds, hobbing 24 123 124 Rs 126 127 28 1210 1214 ris 1216 217 119 1220 12.26 i2as 128 1229 1231 23 24 123s 1237 1238 1239 13: METAL FORMING Shoet and wire gauge 2 pillar die st rect work area 1 erculae work area Diagonal pillar set rectangular work area 4 pillar die set, rect, area Die plate proportions Elect of clearance on tool life Panch—die, clearance Blanking layout Application diagram for press Blanking, nomogram Sheet penetration and trimming allowance Deep drawing and redrawing nomogram Drawing speed 1H/d ratio in deep drawing. Ba 12 133 Ba 135 136 137 138 139 13.10 Bit 132 13 3.14 BusDeep drawing, rect. box ey cup Blank holder force, drawing, nomogram Draw die details 90° Bend allowance V & U Bending, nomogram 90° Bend allowance, Alum. alloys, ironing steel plates Bend limit and bend radii stel sheots Stamping and coining, nomogram Impact extrusion, nomogram Forging, nomogram Lubricants for press work 14; LIMIT GAUGES Limits and allowances on gauges 14. Formulae for gauge dimensions 14.2 Gouge tolerance for checking holes 14.3 Shafts 145 Recommended types of gauges 147 i | ]MATERIALS1 oor oro 1 169°0 os81= 05900 10 sy oro Or oUe't worxesty oe ocsro st 100 10501 $5100 rr ore 010680 Or xoro7 our e100 oro rt oro a 1010507, ost rm oro wor xosro orxon07 ost zo of 00% wrxevo rXo6s't osei—stet sro cw wrx9.0'0 01x 091"0 ue vero peor sco zor ono 1x06 01x 0e7't aot 96800 sodden, iro os 0 o1xasco 01000"! ooct—ostt 00 vont 1889 eu oro ovo1—o16 ece00 seuosg oro-or0 ost oro sorxosco w1xous0 056-006 sravo su eu oto arXae6z owzt 0 ‘unmysog Wo aw ors'0 or xoxo orxsevo 039 200 twnyuory Det 3 vorsrdicg ° sre meoury 79 saradg 3u394h09 SIVISW 40 SILLWISONd TOISAHA DESIGN DATA—PSG TECH.N STANDARD INTERPRETATION OF INDIA » STEEL AND ALUMINIUM DESIGNATION OF § RUCTURAL STEEL: 1, STRUCTUR St, structural eee strength of 320 N/mm? po oe special. limit for phosphorus or sulphur content 2, PLAIN CARBON STEEL: Plain Carbon Steel : Cc 45% i Meade Saresn content in hundredths of a per cent % any of the following: ; , Fusion weldable Wp, pressure» W,, resistance 5, s spot ” 3. ALLOY STEEL: ; i 3 20, 0.2% Carbon ~ 20 Cr 18 Ni 25 Mn 25 * Bee lige, Gheomiam Ni 25, 2.5% Nickel Mn 25, 0.25% Manganese %, any of the following symbols: J,, bright drawn or rolled J,;, precision ground A, non aging quality D, killed deoxidised G, grain size controlled H, hardenability ,, ; M, structural homogeneity 4. TOOL STEEL T 90 * T, Tool steel ; 90, average carbon content in hundredths of a per cent *%, any of the symbols listed below a, annealed _ c, case carburised d, cold drawn h, hot rolled n, normalised 0, spheroidised p, patented q, hardened & tempered 8, stress relieved t, tempered 5. WROUGHT ALUMINIUM (5 DIGIT SYSTEM) 64423 6, Ist digit, major alloying element 1 for unalloyed 2 for copper 3 for Manganese 4 for Silicon 5 for Magnesium 6 for Magnesium. Silicide J ioe Zinc or other elements (Ni, Ti, Cr) 4, oe a indicates rounded off mean value in per cent € major alloying element except elements 4 & 6. ois on a ‘ 5th digits identify the minor alloying elements 6. CAST ALUMINIUM (4 DIGIT SYSTEM) € descending order of their percentage 4680 “ é A eet, major alloying element , second digit indicates rounded off half the mean value 80 Ea of the major alloying element fe end 4th digits identify the minor alloying elements e descending order of percentage Lig DESIGN DATA—PSG TECHINTERPRETATION OF INDIAN STANDARD DESIGNATION OF STEEL AND ALUMINIUM 1, STRUCTURAL STEEL: structural. steel Trinimum tensile strength of 320 N/mm? special. limit for phosphorus or sulphur content sa K 2. PLAIN CARBON STEEL: c 45% G Plain Carbon Stee $8, Average carton content in hundredths of a per cent Hay” of the following W. Fusion weldable Wp, presure We existance Wi Spot ALLOY STEEL: 20 Cr 18 Ni 25 Mn 25% 20, 02% Carbon - Cr 18, 18% Chromium ‘Nickel (0.25% Manganese any of the following symbols: J Bright drawn. or rolled 3h, precision ground fon aging quality Killed deoxiised fain size controlled “denability structural homogeneity 4, TOOL STEEL Tx T, Tool steel 3, ‘tverage carbon content in hundredths of per cent 3 any of the symbols sted below m, annealed © case carburised fold drawn hot rolled normalised pheroidned patented Fardened & tempered “1 5. WROUGHT ALUMINIUM (5 DIGIT SYSTEM) 64423 6, 1st digit, major alloying element for’ unalloved for copper for Manganese for silicon for Magnesium for Magnesium Silicide fer Zine & for ‘other elements (Ni, Ti, CO. 2nd. digit" indicates rounded off mean yalue in per © ‘of the major alloying element except elements 4d 4 423, 3rd, 4th & Sth digits identity the minor alloying elem in the descending order of their percentage 6. CAST ALUMINIUM (4 DIGIT SYSTEM) 4680 Ist digit, major alloying element second digit indicates rounded off half the mean vt in percent of the “major alloying "element 90, Srd"and 4th digits ently the minor alloying clemy in the descending order of peroomage 12 DESIGN DATA—PSG TMEEHANITE CASTINGS : Properties Tensile Yield Youns’s a crath rength module na HEAT RESISTING HR (carbides 280 147000 >300 HS (Nodular sraphteferitc) 420-100 s10-s20 160000 200 HSV (nod graph/peartite 700-840 3510 56x10 m0 HE (lake sraphjrearliie) 170 = zoneo 170 WEAR RESISTING WI (Carbitic/pearitcy 350420 500-00 W2(. fmartensiic) 350420 = = 500-600 WA ( | Irwin) 420-560 400100 WSH (nod. Bp) 700 20 169000 350-500 CORROSION RESISTING CC (Flake sraphiteeaiti 200 + 200 CCR (Flake grapite/Ni austenite) 170 = 130-180 CRS (nod. graphite) Ni austenite) 380 210 Ee 140-200 GeNcRAL GM 6 (fake graphiejsorbo peal) 380 170 15000 3230 GAC peste) 20 0 10000-3200 oc 40, ) 240 ry 115000 16 GE 30 1 ) 210 » 0000 180 Gr 20( fers) 100 © «000 16 aa ¢ bainie) 350 280 SF 60 (Nodular graphieferriisy 420 10 160000 10 sP 80 ( peatitferitc) 560-700 $00 173000 S11 100 ¢ peaite) 0 450 163000 m0 Aes pearlitie bite) 5€0—1260 500-950 £ 225500 DESIGN DATA—PG TECH 13" : : :1D seIMPOU “SST SD € PRD ID Aq pooeidas 29 wD q IOW Z puans opsuoy wr eseasouy ye soseamep Aypedes Suduep -T :ALON wr st f< oF zu fos *2°93#04 100 ‘Apoq rau eouaipoey ua] GT RE 6 > vo sdurep ‘4, “Sp0q yoMYD ose st s< ove a fos 30 sz ty NSD « on ow s © 1p 239 ‘equ ‘an WHET NSO 4H ‘609 und 9p DISH Sa ‘hem ‘una “so “sau We ust oe s» 05 s09/1%91 NIG Or > amsud ,uwyj94 ¢ > sons Suipoog osc o o wi avs s 19 Wee a NSD Ind “Busnoy “sheapynt ‘m8 aut se 5% oF aI sols sa ‘sounjoo ‘spom_ uJ OF > amnseud exo Lt gad oe of % st ZOD/IeT NIC Seu) ¢ 01 pam st sans Sujpuag arog oz « stg nt avs « 199 *297 sa Fupns oct s* os ‘sue “sauysnoy “siss0> pag SIEM L6E Od GH et ae 0 ‘sowie %uo(j84 sop pom aunssad out 3 st 941 01 po ssn BmpUag soy 0% a 8 SI yet NSO st Do sas aa spp Ist une = 2s) Jo s3}2uP SaSQ ONY SaIDWadowa + SONIISVD NOUr Isvo DESIGN DATA—PSG TECH 1.4ose — one sc z ore — oz 0 pH I SA TY#aN3D YOd SONUSVD NOW! ATID ust — s9at_st 4“ oz ous ilove 98 7 000 eu 4 a ose ov psd -p a95 ovz—out - ‘ oe 005 musa) oy aniead oe—06t 7 t ue 0» foo 98 auvod oor—szz - z on cou zlooz Os pataduar 40 ansrod ose—sre = z ow 08 zoos os aumannng w8uang y Yor0 31 wounopaid NBG podusy woneuora spond suas DESIGN DATA—PSG TECH mpandold : NOI BUHZVED UVINGON WO aLHavYD ‘TvaIOWIHaSMECHANICAL PROPERTIES OF HIGH TENSILE CAST STEEL GRADE_& DESIGNATION CHARACTERISTIC 1 2 2 4 3 Ge cn csas css Csi Tensile Strength, kgfimm', min “6 n 85 tos 125 Yield Strength (0.5% Proof stress), kefimm, min 0 7 n 7 102 Reduction in area, % 7 38 30 2 Elongation, % min. "7 15 R 8 s Brinell Hardness, HB, min 190 248 ait 363 tzod Impact Strength, kgf m, min 35 as 28 20 Where due to mass desig, itis not practicable to liquid quench the castings, it may not be possible to achieve the specified impact properties, In such cases the values to be obtained should be agreed to between the purchaser and the manufacturer at the time of enquiry and oréer. | CARBON STEEL CASTINGS : GENERAL USE GRADE & DESIGNATION 7 26-5254 —*. Yield araath, Nin ~~ «SCSSC« | Tene stcogt, Nin i fam sn oe eee & ome oie eee } Reduction in area, ry 31 2s a 24 ij Tagect vale, Non of a ee ee 8 1 kgf = 10N 16 DESIGN DATA—PSG TECH8c0C ‘S13; 2,059 oxdn 9,999 onda a 24088 oxsn Setsk 3.015 oxsn eu Bunt Sugim amet aajen sau Suet >.00r exon 059-009 059-159 059-009 ° 07-009 059-008 vu sve . 7 st u a st uu a wonssu0i9 oy ocr ore ox ar osz Ost tUIn, a Jong 450) os as os ws our oss 910 549 +0 © 49 z 20 G96'—s0e SD TUALVAIANAL HOIH ¥ "RANSSTAd OL GaLIAFENS SONLISYD “TELS AOTIV ©, zp pemx9 0} 304 aumyeioduser BupYI0%) oe i oxz oes soo soo 0 © sto (ast —Mso se « on soo Lo sco (vist 2—ms9 uN sui (cain) % guns 2 anya ydwy wonssb0(a assy 24 (rlsi—95m0—S) + SUALVAAAWAL HOI ¥ AUNSSRId OL GALITANS SONUSYD THALS NOBAVD 17 DESIGN DATA—PSG TECH6 a 2 ose Cr re z out oc xs as soos ms ett sete st oo we os en es é « ost cor co» sv0 . ae ana ca J 5 ge aote g scorponksmox NH ae a $96 — SF SI} SONIISVD THAIS AOTIV INVISISTA LVS oH ssz - = ww = wr z 1 1 eo 9 sx st oer ou I r 1 £20 we a or os r 1 1 z 0 we o one oss Tees 1 sro 139 on sw > Nua 2 . e3 eA (36I-WHE SI: SONLLSYD "HLS INVISISIA NoISONLOD SE| — vvorypaos pauedumer poe pouspieg jo oun UY sBuiios pur eimq 305 ar ans somuadog %s4'0 1 OW NISRINEAVD BSVO WO STEALS "uouee sras> Jo rare *e yoo afeKe 2 62 UW ONIW4aWaL GNV ONINAGAVH WOd STABIS & ss - a 080-0510 ov0-090 399 ss - a» 08'0-05'0 s90-$50 09 $m - or 050-00 050 ol UN $$ 9 sst ov ov't-Or'l sso-sro. 1uW os 3 4 “ 8€ 060-090 sso-sho @0s 3 ex 1 9 06'0-07'0 s'0-or0 ost 0 uc i fe 060-090 svo-seo oor 0 tt ss ce 060-090 OF" 0 ose UN SED ssi le ov0-0€ oro-oco seo aut ss o 060-09 seo-sv0 06 102 - s 060-090 0-0c0 &L UN St 9 out - 4 090-080 00-070 sto 96 Pd 060-090 svo-sro “9 eo st 060-090 oz'0-01r0 SLUW SIO ut - " 070-060 xu 070 $19 ut ss x oL0-0F0 810 - ss i ov0-0F0 x ss 0 5 aH w 84 (ound 3) (payseds ) SLIP 5k puey "uur anpn pa pouug — roedunt poz suorg wiNUTEIA % SHILNSdOWA TWIINVHOGW GALVTEY GNV NOLLSOAWOO ‘TVOINHD GSLAIGdS HLM STHALS NOVI 19 DESIGN DATA—PSG TECHTYPICAL USES OF CARBON STEELS Steel Designation C07, C10 C10 and C14 cis C1SMn75, €20, (25 and C25Ma75, 30 3s c3sMa7s cso 50M C55 and c55Ma75, 60 cos Typical uses Used for cold forming and deep drawing. Rimming quality used for Automobile bodies, cold heading wires and rivets. Killed quality used for forging and heat treating applications. Case hardening steels used for making camshafts, cams, light duty ‘gears, worms, gudgeon pins, selector forks, spindles, pawls, ratchets, chain wheels, tappets, etc. Used for fightiy stressed parts, The material, although easily ‘machinable is not designed specifically for rapid cutting, but is suitable where cold work, such as bending and riveting may be necessary. General purpose steels for low stressed components. Used for cold formed levers- Hardened and tempered tie rods, cables, sprockets, hubs and bushes steel! tubes. Steel for low stressed parts, automobile tubes and fasteners Steel for making low stressed parts in machine structures, cycle and motorcycle frame tubes, fish plates for rails and fasteners. Steel for crankshafts, shafts, spindles, automobile axle beams, push rods, connecting rods, studs, bolts, lightly stressed gears, etc. Steel for spindles of machine tools, bigger gears, bolts and shafts. Steel for making keys, shafts, cylinders, machine components requiring moderate wear resistance. In surface hardened condition it is also suitable for large-pitch worms and gears. Rail steel. Also used for making spike bolts, gear shafts, rocking levers and cylinder liners, Steels used for making gears, cylinders, cams, keys, crank shafts, sprockets and machine parts requiring moderate wear resistance for which toughness is not of primary importance, Steel for making spindles for machine tools, hardened screws and nuts, couplings, crank shafts, axles and pinions, High tensile structural steel for making locomotive carriage and wagon tyres, Typical uses of this steel in the spring industry include engine valve springs, small washers and thin stamped parts. 1.10 DESIGN DATA—PS0 TECH.: CARBON STEELS : PROPERTIES Designation condition tensile yield lod strength strength Impact Nimmt Nimm* value, © 07 sheets, cold rolled and annealed 300-380 c 0 do— 320-40 Case hardened—tefined & quenched 500 5s bars, cold drawn upto 20 diam 500 00, 460 oo | 20 ovr 63 340 cu Case hardened—refined & quenched 00 ss tubes, cold drawn and annealed: 340 130 cold drawn and tempered: 440 380 cus tubes cold drawn and annealed 340 150 Cold drawn & tempered 440 380 sheets, cold rolled & annealed 320-440 © ISMn 75 bars, cold drawn upto 20 dia 520 20-40 40 0-6 |, 40 Over 63 «20 tubes, cold drawn & annealed 340 190 » _-& tempered 440 390 cm bars, cold drawn Upto 20 diam 560 20-40, 540 3 | 480 Over 63 5, “40 sheets, cold rolled & annealed 390-510 ’ tubes, cold drawn & annealed 370 220 : cold drawn & tempered 520 420 cs tubes, cold drawn 4 annealed 390 250 cold drawn & tempered 300 40 tubes, cold drawn é annealed 390 250 : +" & tempered 360 40 cw bars & forgings hardened & tempered 00750 400 3 bars: upto 20. diam 620 0 580 40-63 $40 Over 63 500 cm tubes, cold drawn & annealed 440 230 & tempered 0 500 DESIGN DaTA—PsG TECHCARBON STEEL PROPERTIES (Contd) Designation Condition tensile viel lod strength strength impact N/mm Nimm# Nm Co 35Mn 75 bars & forgings hardened & tempered 00750 400 ss tubes, cold drawn & annealed 40 280 > & tempered «20 500, co bars, cold drawn, upto. 20 iam 60 20-4 oo 8, «0 Over 63, 580 bars & forgings, hardened! and temper 00-750 380 4 bars & forgings, hardened & tempered 00-750 30 4 tubes, cold drawn & annealed 520 340 & tempered 700 0 c 0 bars, cold drawn, upto 20 dia 740 n8 , 680 Over 63 660 bars & forgings, hardened & tempered 700-850 40 tubes, cold drawn & annealed 20 40 & tempered 700 @o C755 M75 bars, cold drawn 720-780 bors & fortings, hardened & tempered 700850 40 © S5.Cr 25 Wear resisting, hardened & tempered 900-1050 o 35 (HN 255 — 31 ‘TENSILE STRENGTH OF STRUCTURAL STEELS : Nim? rade Peis ae nai eh ee o 2 4 7 8 2 Ho 7 0 8 8 = Ee a a eV ave a tensue streng: | 300 320 340 370 390 420 440 470 500 520 530 580 630 880 380 40 460 450 510 $40 540 570 G00 620650 6807101000 1.12 DESIGN DATA—DSG TECH.wonsag #8015 Jo Puy “eC — fyamig Sunny ds = ; supin a Rees payee SS Mle~ ss ue- ste BHZ— 102 we zvi-60 — 60-90 SEO-10 srO-seO #1 49 OF Twe-s8z le-sse Le 60 sso-seo _ BSI-€l seo-10 r0-£0 9p OW 7 UW SE Te-87, le-sse uz she 102 seo-zo SI-EL SeO-10 ¥O-CO «8g OW UW SE le-ssz Uz- 6% ave— 102 - - LI-el seo-ro zvo-zeo +7 UW LE Li-el seo-ro z0-zo UW she- 107 L1Z—-OLT sed oo LI-€l seo-10 +7 UW 0% a E aH g i ON% 9% IN% WH 8% a% uoneuaisoq, i ssouprey ‘ wena z & STIGIS AOTIV JO SULLAIdOUd ‘TVOINVHOTW GILVTAY GNV NOLLISOdWOD gNot= ar E1°F sed wo a90u 1005 208. 2 4 “e OI pry HT 4 Ce €¥-6E LO-¥O seo-10 HO-sz0 +120 FIN OF Me-ssz g's st 0% s01-06 u-w ss 1 09 $6-08 Es w-10 ss ar % S8-O ~— — SL0-S¥O SI-O1 60-90 seo-10 oPo-Co 9000 1 IN se NE-ssz_ g's st 0% soI-05 Ut-e ss Oy 9 6-08 = ew CD 9E-ZE ¥0-S0 svo-seo af IN OP Ne-ssz sy st OL $01-06 Uc-ee ss 1 9 56-08 we-loe S's aI ¥S — S8-OL SO-10 BI-St MED LO-¥O syo-10 S¥O-SEO 4481 OW LIVZ4D Oy TM yyy 8 Oe um sey Wms Iz 8 cit EE SEL TI-GO St-OF MEO Lo-vO seO-10 svO-sro 4408 A TOW £49 OF oH by pT 8 Oct um coy Oe-Ne Ty a 8 szi-olr We-sez sy a 0 — s11-oor Ne-ssz gs st 0% soI-06 Ue-e S's 1 vy Seo (Sto: av0 ve-6z E90 Lo-F0 seo-r0 ¢0-z0 21499 OW £39 Sz m1 ss ar SSB OLls90-s¥O HE-6z MED LO-¥O sCO-10 zO-10 #499 OW £49 SI We-sez gy gt 08 st1-oor Ne-ssz_ g's st 0 so1-06 urns 1 09 $608 we-1e ss ar 8-0 sto-zo tI-60 ~— s0-s0 seo-10 sro-seo #83 OW 149 OF a ssaune 20 Oth 3951 gly yuwlity : . eS fi 4 ssouprey RN wonefuor yifuens WBNS ON OX IN UW % wx 9% woneasisaq wrung Ro SIN PLA stay. (emeo) STIXIS AOTIV 40 SILLWIdONd TVOINVEOaN G4LVTAX GNV NOLUISOaWOD DESIGN DATA—PsG TECH L14Nor= gH T 1g o8ed uo 200 08s —005 O1s—orr un ppp lor— Ire £98-11E Ive-s8z un py 10r— Ibe e9e-11E Ive—s87 Me-ssz UnU Fep lor Ive 9e~T1E Ire-sez_ Me-ssz Lito e9e—11E Tre-sez le-ssz Uc- 6 aH sequinu ssoupzey, wong aw —— SS ee (Pmep) STSAIS AOTIV 40 SULLWAdOUd TVIINVHIIN GALVTAA ANY NOLLISOaWOD vI-60 =— g0-$0 Seo-T0 sso-sro — 01-80 z-s1 90-s0 = a a 99 OW 99 40 € IN OF L0-¥0 ¥0-S0SLt-sez LO-O sCO-10 SEO-LZO .ADOW op DEIN IE SPO-SEO 48% OW 1497 IN OF S€0-70 1-60 SLI-ST'1 LO-¥O sEO- TO-10 €1-60 91-71 LO-¥O SEO-T'0 ShO-SEO +81 OW 1401 INOF - ’ 08! Ovz—06I = 9 OST 00z—09I vr 8 oft amu ¢sy se or oor set—ozt Ir 1 88 szi-o1r ay a 08 001 v1 8 er um coy se or oor sel—ozr ty u By z ss sI vr 9 of ol tw 1 a el ss st ss 91 ty I aP € ss si ss 91 mr j34 anes oe so's=1 gummy quam veda voneSu0ry ySuens pBuans pot IN % ILA suey. wW% 18% ON% 39% Lis DESIGN DATA—PSG TECHCARBON AND CARBON-MANGANESE FREE CUTTING STEELS WITH SPECIFIED CHEMICAL COMPOSITION AND RELATED MECHANICAL PROPERTIES 5 Dalai ic eae a, He - E “ a teva 2 S83 (max) =ga° arte pistues | onsass pap-nes™ Goe!sis don’ see anes 14Mn1S14 100.18 0,050.30 1.20150 0.10-0.18 0.060 44—S4 2 25Mn1$14 020-030 0.25Max 1.00150 010-018 0.060 50-60 20 40S18© 0.35045 0.25 Max 080-120 014-022 0.060 55-6517 13825 0.08018 0.10Max 080-120 020-030 0060 37-49-22 40Mn2S128035—045 025Max 1.30170 0080.15 0060 60-7015 * a, area of cross section 7 1 kef = 10.N Y Steels for Case Carburising ® Steels for Hardening and Tempering 1.16 DESIGN DATA—PSG TECH: TYPICAL USES OF ALLOY STEELS Dengastion Use 2 Mn2 Welded structures, eank sas serng, lever, shatig, spindles, et. 37 Mn 2 Ave, sban, crank shat, connecting rods ee 35 Mn 2 Mo 38 ink shafts, bolts, levers, connecting rods et 35 Ma 2 Mo 38) crx sat, bot, lev, conesting rods worl Gear Conscng ro, ea! Plant par a 40 Cr | Mo 28 Shafts, gears, high tensile bolts and studs. 15 Cr 3 Mo 55) — Components requiring medium to high tensile strength in the nitrided 25 Cr 3 Mo 88§ condition for parts requiring high surface hardness and wear resistance. 40 Cr 3 Mo 1 V 20 Components requiring high tensile strength. 40.Cr2.Al1 Mo 18 Nitrided — components requiring high surface hardness and core strength 40 Ni3 Cold tough steel - used at low temperatures such as in reftigerators and compressors. For heavy forgings, turbine blades, highly stressed. screws, bolts and nuts. 35Ni1Cr6 Aircrafts and heavy vehicle componets 30Ni4 Cr Highly stressed gears and other components requiring ultimate tensile strength of the order of 160 kgf/mm? and where minimum distortion in heat treatment is essential. 40 Ni 1Cr1Mo15 General machine parts like bolts, gears etc 40 Ni2Cr1Mo 28 High strength machine parts like collets, spindles, bolts, gears ete. 3INi3Cr85Mo55 Highly stressed bolts, shafts, gears, mandrels, aircraft power units and for low temperature service. 14Ma1$ 14 Parts where good machinability and finish are important. 40 Mn 28 12 Heat treated axles and shafts (not recommended for forgings in which transverse properties are important.) 17Mn 1 Cr 95 Small gear wheels, shafts, cardan joints and chain wheels. I5Ni2Cr1Mo15 Heavy duty components, gears and super charger gears. 13 Ni3.Cr 80 Heavy duty gears, pinions ete. Very highly stressed machine parts which are to be hardened with high strength and toughness in core after hardening 55 Si 2 Mn 90 Used for springs in the hardened and tempered condition 50 Cr 1 v 23° DESIGN DATA—PSG TECH 1.17is: 1570) ALLOY STEELS : Properties tensile Pane uae BHN dition es N/mm! re Designation cond! 440 to 700 14 to 62 170—31] 240 69 Gr 13 bars & forgings, sco te 105° idiniees & heat resisting hardened & tempered 0 steel) ,, softened ee s strip, she tene a Fold drawn & softened 500—7 420—540 240 Creep resisting bars, forgings 10 Mo 55 ag & plates, normalised 470 260 2 Plates, bars, aes forgings : hot rolled AO or normalised 600 55 case hardened, refined and quenched (core property) 15 Or 705 case hardened, refined & quenched 600 48 15 Cr 90 Mo 55 Creep resisting, bars & plates, = rx normalised and tempered a 300 55 640 bars & forgings, normalised and tempered 440 240 tubes, creep resisting as PS ,Gr SMe: 55 creep resisting; 600 bars & forgings to 440 48 normalised & tempered 740 tubes 480 260 Re ee iS Gr 33 bars & forgings: 600 440 (stainless & heat hardened and to to es 170—311 resisting) tempered 1050 700 62 sheets, strips: » softened 500 » hardened & tempered 700— 1000 500—760 tubes, annealed 450 300 » hardened & tempered 600 500 a ae aE ae a Ns ee 16 Ni 80 Cr 60 case hardened, 700 4] refined & quenched (core) Scie ROBE tei) ee ae ee 2 ae eek SER ae EEE 17 Mn 1 Cr 95 —do— 800 95 35 20 Mn Cr 1 —do— 1000 38 20 Mo 55 cree isti i 55 p resisting forgings, bars & plates, normalised yee “ 20 Cr 5 Mo 55 creep resisting forgings & bars 700—850 540 4 > 1, air hardened & tempered 20 Mo 55 tubes, creep resisting 460 250 fe 1.18 : DESIGN DATA—PSG TECHALLOY STEELS : Properties (I'S : 1570 ‘ena a ee Designation condition on srensth vale o mer New ‘Nin orc bars & forgings (Stainless & beat resting hardened tempered © fo 1080 440.10 700 410 62 170-31 sel) Toftened 3 240 6 she stp, fotensd 450 Cold dawn & softened 500-700 10 Mo 55 Creep resisting bars, forgings 420-540 40 & plates, normalised Mn 2 Plates, bars 470 forgings = ot rolled we 20 or normalised Sto case hardened, refined and 0 ss Shenched (core propery) 15 cr 6s case hardened, refined & quenched 600 “ 15 Cr 90 Mo 55 Creep resisting, bars & plates, formalised and tempered so 3005s eo 40 IS Cr 3 Mo $5 creep setting «0 tare & forgings ~o «8 ormallead & tempered 0 tubes i 20 15 cra bars & fornngs: «0 wo 4 Gtainess heat hardened und c ttl Ae 170-30 reaping) tempered 1050 m™ @ sheets, tis: pardened & tempered 16 Ni 80 Cr case hardened, 700 4a me Fefined & quenched (core) 17 Mn 1 Cr 95 ae 00 4s 20 Ma crt io 1000 * 20 Mo 55 creep resisting forgings, bars & 480-620-2805, plates, normalised 20 Cr 5 Mo 55 ‘tcep resisting forgings & bars, 700-850 54 sic hardened & tempered 20 Mo $5 tubes, creep resisting 40 250 118 DESION DATA—PSG TEC; ALLOY STEEL : Properties (Contd) tele, yale Designation Condition Strength strength Yale BEN Nom Nome “Nm : in 2 Plates, bars , forgings: 300 230 e™ ‘hot rolled or normalised to to «30 i bars; cold drawn 700800 Sheeis and stripes : softened +20 fot rolled of normalised or orm & tempered" 550 irdoned & tempered 00-1000 tubes: annealed 420 220 cold drawn & tempered 500 io c) om 20 Cr Ni2 bars & forgings, 21 235 (tails de beat Rindened ad pered m0 FA raising) 8 a Sheet & strip, softened 630 3; hardened & tempered 500 “ : wit, cold drawn 700850 ; m sonened 0-800 21 Crt Mo 28 Sheets, strips hardened & tempered 115013501000 v e0ld rolled & tempered #001000 620, tubes: normalised & tempered $6080 460650 ardoned & tempered 000 : cs Shect, hardened & tempered 700-900 500-760 sinless & heat softened 30, : resting) Wire, So 00350 : 22 Cr 13 8 28 bars & forgings (Suaintess hardened & tempered 0-930 Moo 3s ETT ; E = Mn 2 Plates: bars & forgings sso 300 : he lled or normalised to to ; fo 30 : Tubes; cold drawn & tempered 560 0 ‘° ‘o ; so so ; WNi4G1 Tube, hardened & tempered «11001300 900-1100 : 30.ce13 bars & forpings : ta & bea Inrdened tempered 0-108 40-082 Sheet, softened 0 hardened & tempered 1600 Wire, cold drawn 700-850 2 ON sotend, e000 MNS Cr 65 Mo 55 1200 1000 38.Cr1 Mo 65. 25 Creep resisting, bars & s00—1050 7048 forgings, nocmalised & tempered DESIGN DATA—PSG TECH 119ALLOY STEELS : Properties (Contd.) teasle yield Trod Designation Condition strength strength Impact BHN Nimm* "Nim Nm crt ‘Tube, hardened & tempered 1100 900 40 Cr 1 Mo 28 Tube, 79 00 ce or cold drawn & tempered 4 Cr 1 Mo 60 Creep resisting, bars & forgings, a oll hardened & tempered 900-1150 700-800 48-85 40 Cr Ni 14W 3 Si2 Valve Steet, softened a 269 sScr9sia Valve stel, hard & tempered 255293 47 Mn 2 Sheet & strip, cold rolled. & tempered 9001100750 hardened & 1130-1350 1000 55 Cr 70 ‘Wear resisting, hardened 300 om 3 25531 s ‘and tempered to 1030 8 Cr2Si2Ni1 Valve steel, hardened & tempered. 269-102 TOOL STEELS : Hardness the annealed condidtion (max) Designation BEN Designation BUN For cold work Tous 210 T 90 Ma 2 WS0 Cr 45 20 T 70 200 TCV 2 20 T © 40 T 55 Ni2 Cr 65 Mo 30 ass as a, TIONI4CrI 235 ean = T 15 WI8 Co6 Cr 4 269 Vi Mo 75 T 105 cri 230 ri T 83 Mo W6 Cr 4 v2 28 T 28 Griz 260 For Hot Work T 160 Ce 12 20 T35.Ce5 Mo VI 29 T 140 W4cr 50 250 T 35 Cr 5 Mo Wi V 30 29 Tilw2ct 20 1.20 DESIGN DATA—PSG TECH— f0-s10 OI-S0 RESSSLY,. Urs S0-sz0 SeO-10 *NSTO 86s AGLONS DOI L $9688 - Vornxat wor 1D vs Sy Toys ssc¥ giv ua = onst sTeN TIVE = - St xm zing 35 Ton Zs soe 8 oorzs 1603 A) HD SOI ote UN 120 SOF = - stxm Laing cons = 35 108 1s woh Teug CM) $2 sor sow Sev us oor tsa 19 so 5198 3 zea - = vexHur - we ¥ 06 = omer eNO STON st - - - - Vor wa SPNOK OWL LD FINO “ ee. = orig 20 TONS eee THU - - HX OF30 1D stv = - - rsh wor YS ovle ous — om = BONse - LQON oF VAX HOF 8 WONS oncy YT FON IN IDSC THEOL OW T-OTINOF - - x30 Isivays 900 wa £49 $1 ss 8505 10s, as ort oct Bost HONaU. NVFVit NYisso’ — GSNYaVE = NVORGRV -HSUNIE NVWYIO—_HOaZ NVIGNT GONSV. Na 1805) Sir Iv. ‘Sa Nic NSO. SI (Piwe9) SEREINNOD WIHIO sO SINTIVAINDA ISTUVAN UIGHL GNY STHFIS CUVGNVIS NVIGNE 1.25 DESIGN DATA—PSG TECHPROPERTIES OF BRASSES OF DIFFERENT CHEMICAL COMPOSITIONS ‘CHEMICAL COMPOSITION Tensile % Elon Brinell ¥ * Strength Hardness % % % tion® tea Pb a a 54-47 = upto2.5 Rest >45 «10 110 $7-39.5 1.0-3.0 Rest 37-68 92 to 25 9-170 595-62 upto0.3 Rest 4-59 3to 30 «80-170 62-65 upto 0.2 Rest 30-70 Sto 45 70-160 66-69 uptoOl Rest «29-54 St0.45 70-160 95-73 upto0.07 Rest %-$3 Sto44 © 70-155 * Gauge Length 8 8 Round test piece; 4, Area of cross section CHEMICAL COMPOSITION & PROPERTIES OF TIN BRONZE ‘CHEMICAL COMPOSITION MECHANICAL PROPERTIES Tensile % Elongation _Brinell yeu MSn in PD we Strength Gauge length Hardness errs 5 kgf/mm S8ya* HB % 4 - = <04 3245 10-55 65120 4 6 eo <04 35-50 12 70—130 Stet = = <04 40-55 20-60 90-150 Basten oe 03 55 5 150 Ble oh =e = 2 15 C) Reargpele tse tee Je fe 28 8 80-95 Bree nsis | eo - 2 3 85 as 5 casas = 15-25 10-12 6015 Boe chr aris - 20 10 65 a, area of cross section, round. ———— eee 1 kgf = 10.N 1.26 DESIGN DATA—PSG TECH1.27 tT! =P str wo Ord 100 oro soo —or0 — -80 — — THNSO ~URMY sI-SI —SLO adstasius I =p ss 0 Oro 100 oro soOstOOr0 — — — — LO-E0 ~wRuY sI-F -S¥ adstasses 90: St St =p sro — 00 of soo —Or0 — -€0 -LO -80TI-BO -wRMY 9I-PI L-s aaslasoS 9 =p sor wo Ord 100 O10 soo oro oro — — = O1-$0 -uruey st-El -S'6 Gaplasolus OF st 2p 0 V0 100 oro sooo oo oro — — = =StT -remy 91H IZ-6I GasTasocUs Oz 2p zo oro 100 s0 sO SIO Or0 — — = SE-St BMY ZI-II 19-65 GaITgSO9ES 09 m0 oro — 800 S00 STO OTOTE-e =— — — HI-OI WED xUTO OL-89 OETZEPTS 69 sve »p LO 00 B00 S00 sO Or0 HO — = — — — ~SLE “BEM ZI-O H—-*L AAITASSLOS SL v0 of 8000 S00 soo oro %m0 — — — — 9-S XHEO II-6 WINK SmOOIasHS +8 se st SO $010 8090 S00 sooo O10 30 — ii = @ ov sv of wz sy x “XVW '% ‘SaLLNdWI — -— st mWEO -$9 MNOS ENOLasUS Wh 9a 5 nog) oe xOTIV gavuo| g ‘SLNSINTTA ONIAOTIV DOSIGN DATA—PS0 TRCH SKOTIV ONRIV#H NOLIN -LINY 40 NOLLISOdWOD TVOINEHDPOURING TEMPERATURE RANGES AND TYPICAL USES OF ANTI- FRICTION BEARING ALLOYS Grade Pouring Temperature *C ‘Typical Uses 90 au 8 20 10 340 to 390 430 to 460 360 to 400 500 appprox 370 to 400 370 to 410 500 to 530 350 to 390 For lining of petrol and diese! engine bearing, cross heads in steam engine and other bearings used at high speeds. (As tin content drops in these alloys, their resistance to shock and load increases) Mostly used for repair jobs in mills and marine installations. (Because of its long plastic range, it can be spread in as a wipe joint) For under water applications as a bearing alloy and sland packings. For lining of bearings required for medium speed: such as Centrifugal pumps, Circular saws, Convertors, Dynamos and electrical motors. For low speed bearings, such as pulp Crushers, Concrete mixers and rope conveyors, Heavy duty bearings, rolling mill bearings in sugar, rubber, paper, steel industries etc. Bearings for diesel ‘engines, Cross-heads in steam engines, turbines ete. Generally for heavy duty jobs. For mill shaftings, railway Carriage and wagon bearings Usea as a thin line overlay on steel strips where the ‘white metal lining material is 0.076 mm thick. 1.28 DESIGN DATA—PSG TECH“Die siayDEI9 poss ons ‘suoAo] Sa7eIH960 st Yyons pannbo st soumstss yooys pue Aynonp qa yBusns wi siya sBunse svo=tO+ BME SN iy om punt ag At el 20" peeg UC EK, svo £05 \2cg 510. coe ny 8W-I¥ ‘Bur hy smeougyostw pue unseo op aimed yoo=ug eo eee acerca a PEMRia tere Sec. TOs 0-108 soo 90 ro UY oo sKouy Isiy 210 so ‘S400 ped ‘amd oanow som se qons dur oT Beg apie 0 fy pe ae ainia a 170 eo eo suo 99 oo _fh Pam 09 Uz =n ome NY WK S% S% PO% ad% c1% WW% TO% W% wz% wonduosogq 20 SAOTIV DNLISVD Zid JO SHSM GNY NOLLISOaWOO 1.29 DESIGN DATA—P8G TECHig se OT OT a 5 BS Mt SS me me om spout os Hr tw romm+o of fe St of SS me ce ro paeuen — oooes SOmINHO Ht Ee OOO separewee 00s a cots aie ed ee ees ee sromrn coon ff 8 oo - wm - - 2 epuewru oper 2 ost : ots ue om o uf MM eo to Lo Oh Oh pu HSE o 2 = ro tO se ° oo ost ’ ots : uo ° x oo : 7 = a : oot ' ose o SL Of z rr 80 os ot %- 4 a co co me oo OO € $0 To Ft puma sree soemtmmiaest 9 Ne — — 10 suo yo £0 — soo murs OOseL or ezine WI a 99 Ke — = ro ro co s0_co_ ro ume amet SMR ce 4 g gk RS ge gf 3 2 go 2 me! 5 = te 8 be Pp eb heise ae A ik tt Pp PR oie ae en Ho 7 58 SEE e # sg 6 e 5 baer aa 8 a ee S2500W14 ONRERINIONE IVWAND WOK SAOTIY WAININGIV ¥ WAININMIY LHONOWM 4O NOLISOAWOD TOUNAHD 2‘jue wonewioyoy 20} wan are puY sont [WEA AMO axe JedkUeY WY UF semEdoZd, ‘ t t ‘ s £0 § + Lo § -zo > fs ur ems ff sane 15 ro UN we tL zo co -ro ‘ t t tr i o a Sav OWN. sco ro oF 8! 90 bo we me Se ay Reenter sea A or - = omm -— — or #0 ° ox t ost t a i € f oe H or ro zo zo 90 fi = g g sf Be 3 F ee ee 2 @ Ope wy» F come 3 Gs ze GE Boch tee Peed tage Fog gs ie ofiey Bow eg Beounluads a i Rone ais & 0 -ro #0 -ro oom st -o1 zt +0. et 0 60 -ro cangoutey zo vo sro sepurwey —ofs¥L sspuruy 70059 puRUY —OFH sepureuy —ezH49 epuremey ore voneutiseq wopurmy (eemepwe>)—SaSOdUNd ONNIFANIONS TVEANAD HOM SAOTIV WNININTTY GNY WAINIAIIY LHONOWM JO NOLLISOAWOD TVOINSHD 131 DESIGN DATA—PSG TECHaraydsoune susew ut syeradss “yore 2aysou0o 0} ours yBty 24nH “yBNO} sfurtu0y pur sue ‘sqm) — ipuiiy> Funwore9 “Aypides suapsey DESIGN DATA—PSG TECH ‘ssouepdd onsowop pur 40% yersu yous s8un}01 ‘vorsnpea ‘owed “295 ‘low 1nq “uopueD yor uy apron, coors uyesg 20} —op— —op— 00094 Suuopjos pur Suz019 ‘Buypjam 01 10M ‘Super 20} 230% 296 Pos papor pur sum RSH SPU Pue pawoy Ase> s} coer pues say ur Auponp ares sey pur yuounean ‘uonersprsuos Kuewhd jos! sBulfu0y puw pos potas \puane yity asoy saumonns Jomo pue yersye uF sued posang ‘asm “aqny ‘oorsnaN, ns poBe st reuy oye Suons weste fe quonbosgns sued pur ‘supubUIeTe pus suoysnane> ‘eegs pep Jo uorresndde yerure “owrodw youn jo axe “Buoy pur astm ‘aqnr ‘seruadoad reoqunyoou yy azsy SsIMNIE eBuHBIOg Ainp Kawogs — wager, ‘ned aEKS sreve onpeeys ges pur Aiamat ‘sw Ayn Pazypoue pur passaid ‘si0}oyar ‘sh rou ‘sada pur yur ‘alunos pu fwawdinbe fuyssmoud puw Suyasiq ‘feoUoys ‘poo} ‘ueuMUES pos poor ‘asym ‘sqm Papnanxa yd ‘soy JaBuong vo BuIppED UMN: UoIsOHIOD “vo ‘n oos61 sound eomnae ‘aH Supra BuIppep ‘sed wnesp dap “are MOTION unds ‘asm yg oH yeu yoys ‘spsuaIn uryoos “Fupyeed ‘eaunpa B4}IG PAP pod} ‘uBio pur aun ‘oan, 20} yooudmby Bugny vonessfujy ‘Suypmnout pue ‘uoysnanea ‘ood “2045 00061 oneuaissct 980, eK suiog aguueay 1:32 SAOTIV WAININIIV LHONOWM “IVDIKL JO SYS GNY SOLISRGLLOVEVHD1,33 22 ‘syse0o yes pur fi sye5834 aunesaud “s9;p0q_ yon 2 Pe se yor sBuppm Buns ue worsnsnx> “9d “2945 ocsee 26059 ‘Iuuooy pe ssouyewue® umesp doop “eourE}ueD NU sourewuca 8129 ‘H 3001 ‘souei5 ‘safpug ‘sopyyse —— “sBushuoy pur aim ‘oq wodsuen peos put ‘uosmang ‘one 294s ocr se yons Aunqeoyoe ns weodut 5 ses pany cone9 susuodwoo ew pur op. overs, pur qn, auyssaroud ‘wos ‘aid “24s vars 404 se coves argenresy vonvutisoc INNTV XHONOWM TVDIKL 40 S¥SN GNY SOLLSRESIOVAVHD = skony wi DESIGN DATA—rsG TECHst sco sor am oor ~ - wm ro = — 0 so 90 -So oz —sto oe sasz nN a ssc co os ~ purg. - “ oc wu soo sy 00 =— 10 Tro 10 sto sto 10 oF on mo - w sie ow ~ pors = 2 a wu soo so TO” — ro ro ro sto sco —s6 10 ons ey - z od vo on 90 W ors, - st {1 ee sm ro ro = — ro ro —r0 90 ro se as = € W ows - c wu soo ro to 6 «1 ro so vo Fo sr mo - L prs - 5 wu soo ro — = 10:10 roe sa ro ons 1 = s vo w urs - £ wu 0 S00 ro 86 = ro sro ro 90 TO ors cy - t vo 09 ov w urs, = z wu soo ro — 70 so fo —ro #0 —oy sro —oz ee rey = = su st w pars, - we co co ro ot aor oe om ey ey = - W urs, = = wu ro fo — — rt 50 90 oF ve sro 9s om ‘won won P80 v eg ant eet WSS sod TUORIBOSWES TwOBHD ‘st SAOTIV WOININNTY IVD JO SALLWAdOWd TVOINVHOTW GNV NOLLISOaWOO ‘TVOIWaHD DESIGN DATA—PSG TECH 1.34an an p00) mw a st ms e s nm a ’ pors = £ iced re & pars, - z 18% cot = pors 01 mo cor pars cor sad supaey wen tune, war soo soo 500 soo x0 so s6 1 09 ov 09 sb sy oe ey oer sap saz 1.35 DESIGN DATA—Ps0 TeCHL5 2 setanses ap Gysest_ pu 3 sags purr be porn AoW, o WI 005s a § stones xp used pus & sdupses puws se porn. <1UreW 6 WI ser 8 sygepton “stunse> aroun! ‘stanees ap (038 pas stun Joy aygenms “uosoues, on 2oueN sano pues © pom AHL ue wbeby sutsend “ADIT. POD sma oxy sunses sp _amssad_ pur Anveid pat anne pust se a@enS 91 coor -stanses xp Kyat suns pore 5 ponh AIT $s NT ows “ap smnsond pur Aes sve pin sat0q ses oc0g 2 por sdunae> pons se apg ‘Snea ula pea apay/® sapouorty yw exer suyeeo 2p Joneq_seupsey pat cunomed 8 pest A sine sjgrvod — stumiea youn 0 Stustoq So1oW “yan asnerid’ pe z WT sr tones op yt se pon AOE ret ‘Tapees yo pomiom popusanaaaey epee eaaK, SasaerD wouwaip ‘Sa s Paes ne aen a Pon eC ene oa eaL ee 3 SNOLLVOTIdaY ¥ SOLSRELLOVAVHD — SKOTIY WOININATY IS¥D e1.37 uses ap sansa se pan, ” WI ow ssBunses opp Sysest se oer, wz wI rer 1 WT oocy 91 WT ster sBunse xp Ayues8 pur sfuyjea pws 50 pon + OWT od svam o1 somes poof ‘uowsuedx> Teulsoy) Jo 1u3!4j309 Mo} pul WiTuasIS simesdus) Gay ARB POD ont sor suo 40} sBunse> ap funesd put zu WT sasz ‘unse> pues se posn cept ‘stoner ap ued pur ‘Supe pues $e porn AUT WI once Fupses Jo poyeu papusunuoooy = ‘woneuBisop ——worreulisap sa SI DESIGN DATA—PsG TECHCONVERSION OF HARDNESS NUMBERS AND THEIR CORRELATION WITH TENSILE STRENGTH Brg Hae Rockwel Harioes HOR Tene strength Ninas* ¢ Bar be oe nr ty g sale Bere g ey i aug itis Beran Pac A AP ORNS ads dae etal i ede Bee a ee ae ee =e eee Se eS ag ee ate Sie et egg at) Sey = aie igalec gee Weer 932 merc Te ae eS res Be eeehy qr > ayeae oo oter Paect) = = Bay tea yeh ate) ay Signa: eee Se oe Be ties ne.” arco. aie? use oe = Peuiernt at te “a's tee rei) ete. a i coy ee ECE: Suge ogee = Bian Res eee et, Freee: hai eee ae 210 aps ube. Sse ewy ws eae a Bsr aed oh, ae c= bh cgn y pT, toa ae 20 488 46S mote 810 Pit gaan? ian) “aes! = Se 2ee 82 gee tee ieee Ps 290 Need wis si acct an: Se eee nee, eta fee 29s age BEETS Ee Lae RE isi o> ie) 4" Te 3.00 Me ms etoEi clas Os wk?) Meee anes | age 3.02 Hehe aes ee a) 8) ans Shp es sues Sues, || ae 3.05 P aetcuella Soh eae Restate et 310 Mh ae, ate a A piste ee us OO c= emt eee Beep pa 320 » mo «IMs ms 32s Be bie. Isic kg ahs el Sako ie 330 Hse oe 2. yee Se p's, ate Petit alee 335 ict a BS is es 1190 340 Reese ca SE “ 1201090 nas Paar STs toms 08 30 Rah eas ceo “toss ons as Geta". Ae 6 iss ims 1000 30 hee et = 2 00 toss 36s eae ote rar 8H 30 eg 0 90 so sis 375 Beet ae Gee » os BS 340 Bepeicar a x 50 as 38s elisa 7 BS mm ous 330 eT) 3% om rr) 39s @ 8 ows esos 400 eo 3 ug mo 7s dos “om 3 wo ms ‘10 » «9 3 1 er) ais ie ae 2 Ww “0 oT 420 ns @ 8 2m ms ms 435 ee ere a x oho mo ats ) to 1g M78 as ws 435 Bee ne x 60 oo 6 1,38 DESIGN DATA—PSG TECH. ia ot CONVERSION OF HARDNESS NUMBERS AND THEIR CORREI ATION WITH TENSILE STRENGTH (Contd) Brinell Hardness Number ee Es : g Tensile strength N/mm* ‘ f¢ oe : £ @ 5 Scale Be § : g 20a eee EE OBL eee es @2 ec A B =y Ez Es ES gag ca m 2 a 91 186 os 675 655 635 4.50 179 = 56 - Pe ca se < eo ia a ay 88 177 a= 640 625 605 be a 35 87 174 oe 625 610 590 rs Fa 86 171 ze 610 595 580 4.65 166 — — 85 165 ios 600 585 570 4.70 163 —_ pt 84 162 bs 585 570 555 ce 1S? ri = 83 159 & 575 555 545 am ass = = 82 154 a 560 545 530 a:55 ie = — 81 152 = 550 935 520 4.90 149 7 = 80 149 = 535 520 505 4.95 146 5 — 78 147 a 525 510 500 5.00 143 = -- 16 144 = 510 495 485 5.05 140 — ae 16 — wi 500 490 475 5.10 137 a _ 75 au i 495 480 465 5.15 134 = o 74 = = 486 470 455 5.20 131 = _ 72 os = 470 455 445 5:25; 128 — 2 71 x = 462 447 435 5.30 126 — - 69 oe = 450 435 425 5.35 124 = — 69 = — 440 430 420 5.40 121 — = 67 a = 435 425 410 S45 2g 818 a a 66 = ae 425 415 400 5.50 116 — a 65 a a 417 407 393 5.55 114 = a 64 = = 412 402 387 5.60 112 — — 62 — = 405 395 385 5.65 109 — a 61 _ = 390 — — 5.70 107 — — a os 385 = _ StS aa 105 = a 58 == oo ae ie 380 — — S80; gee 103 — _ 57 — — 370 — -= 5.85 101 = — 56 = = 365 a = 5.90 99 eg 54 os = 355 = a 5.95 97 —_ = 53 = a 350 — a 6.00 96 — — 52 — a 345 Bis a — 6.10 92 — — 49.5 —_ _— 330 jai a 6.20 88 = — 47 — — 320 a a 6.36 84 a ee 43.5 — = 300 a a Rie acto = ee 40.5 i = 290 a fe _— — 38.5 _ — 280 — _ > BETWEENMATERIALS FOR GEARS Material 8 Tensile Binal cfation irenath hardness re Nina umber Grey Cast Iron ade 25 230 7 Phosphor Sand Cast 160 o | Bronze hilt Cast, 240 7 } Centigally Cast x0 0 i Cast steet Grade 1 50 us | ea Fos ee 5 } Coostructional Stet se 58 590-680 160-190 | Plain Carbon Stes! co 00-700 180-200 Caron stel for cas 700 145 Core | furfacte 4 Case hardening cs 720 200 Core 520 Case | Carbon steel for case cu 00 150 650 Case | hardening | Direct hardening 40 Ni2 Ce 1 Mo 28 1550 “4 Alloy steels 30NI4.Cr1 1000—1150 400500 | 35 Ni1 Cr 1150 400-500 ania 730-1050 400-500 Alloy Steels 17 Mo 1 Cr 98 001100 650 Case for cate hardening 15 Ni2 Cet Mo 15 1040 690 Case 13 Ni3 Cr a0 900-1200 00-620 Case IS Nid Cet 12001500 (00-680 Case 15 ce 6s 0-850 650 Case Nitriing Alloy steel 40.Cr2 ALI Mo 18 > 660 750800 Case } li | 1.40 DESION DATA—PSG TECHPron — = pero — 7 SS sumdowioul — a Aupecoueq, — SL !ALON sexosony 1% a one - se y * 41 saahqsosonynosoresiog “ s ssw - " s W a RD ouapyuansog Guta) voyey zz , ox " u x Ww aL ——_eakqaorongenersiog vomo ‘woumy work = 60 t nx au ez a « a suarkuatiog -edepox ‘mums spomend TT cow - on ze w a suey s501mNe wt * ane 6 se a * a apresiod ‘saath “nig “amet st saw ” o st " a suaukssoa waded ‘smxoyd “oT OFT « oor © 6 9s « AL aera yopaur Mog “won ‘owond ‘wor wi %5 ow - 1 9s W a (vanonengon) PHO KKMA. AO Tommy ‘amse, ‘4025 zt @ sou - a %s H a arnonD KaM Mod vormd ‘mays ope YT SOT an ou su ® « su ncyopreioy main une sums es 2H) on ‘ommuod ‘amp omeng = stl At oor Ww vr sm 8s 95 su ansqertreuerousdd mw) yyy Suey gummy seapreg hans uae ituane sours apes sues 01x wpe may” easencinoy — “sua = wompuey aK, mew DESIGN DATA—P8G TECHAPPROXIMATE VALUES OF ENDURANCE LIMIT FOR STEELS: Loading Reversed cycle Repeated cycle ‘Tension-compression oy, = 0.36 0, oq = 0.5 0,<¢, Bending o-ay= 0.46 oy 6 ey y aye amonns jo Aaqeuyseus 30 woussaxdusy (¢ SunopY SNS (z wes (1 ‘woneBasBos pu sto easn09 ai ‘sun ‘uquopsey 40} aumsnins Jo uonssedaid (y ‘moypeosg pjo> jo wousrosday (¢ upoyar ssans_ (2 ‘un Suixaqs seas Suwayjos. (1 sroding ayooo se Aq pamortoy aunyesodus Burg0M p09 Jo spe IV ouue rskasoy ou uy 1 +v pue suse ors 3867 a soeuiny om ut ost res ayn 30 3 Say 0} us 0¢ 01 07—"ov ~, of o10¢+>¥ “f sion Koy ox a01+'v P bv > oy us 20014 01d p05 jooacy SINJIWLVSUL DNTIVANNY JO SOIOHO a3 DISIGN DATA—PSG TECH@ 400-- pe a gy ---A----4 —-f-----}----- S Mra & 00h i = pe TTT DIAGRAM FOR EN@ & C404 see AUSTENITIZING TEMP. 625°C voof- 2 pido] as) |e 2S TS 80 4012S ISO Sec min hr day 2.4 HARONESS , Re DURATION OF ISOTHERMAL TREATMENT eos 901) 6 ° Teele END QUENCH HARDENABILITY CURVE FOR ENe & C40 STEELS 20 40 60 DISTANCE FROM END, mm DESIGN DATA—PSG TECHrc TEMPERATURE 800 700 600 500 400 300 200 100 3 0 TTT DIAGRAM FOR END & CSS AUSTENITIZING TEMP. 825°C 20401 2 5 1020 401 2 5 10 201 min hr day DURATION OF ISOTHERMAL TREATMENT ae 6 HARDNESS , Re 6.536 ° ND QUENCH ENABILITY 20 “40 oO DISTANCE FROM END, mmTEMPERATURE ,"C 2.6 800 a eet ing 7 ee pac 700 a 600 soo. 400 LF ———_—__ 300} . td = Mea 200 b TTT DIAGRAM FOR'EN 24 & 2 4 ONi 2Cr1Mo 28 AUSTENITIZING TEMP: 835°C Lot 4 1 1 1 uJ ' 240! 2 § 10 20401 2 5 0 2! Sec min hr day DURATION OF ISOTHERMAL TREATMENT Re HARONESS, ° END QUENCH HARDENABILITY CURVE FOR EN24 &40Ni 2Cr 1 Mo 28 STEELS 20 40 60 DISTANCE FROM END,imm DESIGN DATA—PSG TECHSALT MIXTURES FREQUENTLY USED FOR HEA’ \TING IN SALT BATHS FOR HARDENING fature components ‘Chemical weight ‘Melting ‘Recommended temp. 2 - formula % Point range °C Common Salt Nal 50 560 590 — 900! Soda ash Nay CO, 0 Common Salt Nact 50 59s 610 — 850 Calum chloride CaCh 0 ‘Common Salt Nact ns 6s 65 — $70 Barium Chloride Bach, 5 Common Salt Nac “4 6 720 — 900 Potassium Chloride kal 56 Common Salt Nal 100 $00 830 — 1100 Barium Chloride Bact, 100 962 1100 — 1350 COMPOSITIONS & OPERATING TEMPERATURES FOR SALT BATHS USED IN HEAT TREATMENT Composition of bath, *% 2 5 $B opetes a o2e me ye 4 Book of g Z 3-50 0-10 50-60 : 163 0 598 as E -— 67 = 28S to 595 650 5 i 10-15 25-30 40-45 15-20 580-158 790 g é é 5 45-55 2090 0 S s 620930 240 & 2-32 50-0 595900 oa APPROXIMATE HEATING TIME FOR STEELS IN VARIOUS TYPES OF FURNACES a ine per tom dia or theta of ance Fenpre sauie Testing etic Furnace s00 09 0-0 os 01 Furnace $00 3540 1550 ss Salt Bath 200 os 1s em Lead Bath 0 os * 12 Salt Bath 1300 os ‘ 10-12 DESIGN DATA—PsG TECH. 27CHARACTERISTICS OF COMMON METALS WITH THEIR ANNEALING AND HOT WORKING TEMPERATURES Lowest re- Usual annealing Workability at Usual hot-working Meal oom temperate a eee ve remerature range °C Aluminium Very good 150 350 320-480 Brass Very good 200 540680 590-300 Bronze Pair 400 540680 590-900 ‘Copper Very good 200 540-760 430-1040 Duralumin Good 260 340-355 320-455 Gold Excellent 200 260-540 . Iron Good 450 590-760 820-1320 Lad Baxcllent Below room Agneals itself : Monel-Meu! Fair «0 730~790 70-1150 Nickel Fale 590 590-950 870-1260 High carbon steel Poor 0 590-760 760-1090 Silver Excelient 200 260-540 x Tia Exeaiont Below 09m Annals itself : Tungsten Poor 1200 12051370 590-1590 Wrought iron Poor 480 Not cold-worked 900-1340 * Heating not necessary, 28 DESIGN DATA—PSG TECHHARDENING AND TEMPERING TREATMENTS FOR CARBON AND ALBOY STEELS (Hot Working Temperature Range for all the following Stecls is 1200°—850°C ‘except for those underlined below) Designation 30 35 Ma 75 co 55 Ma 75 40518 40Ma 2s 12 20Mn2 27Mn2 37Mn2 40Cr1 35 Mn2 Mo 28 35 Mn 2 Mo 45 35 Nil Cr60 40 NiCr 1 Mo 15 40 Ni2 Cr 1 Mo 28 31 Ni3 Cr 85 Mo 56 30Ni4Cri 15 Cr3 Mo 55 25Cr 3 Mo 58 40Cr3 Mo 1 V.20 40Cr2 ALI Mo 18 55€r70 105Cr 1 105 Cr 1 Mn 60 * Stabilisation 550°C DESIGN DATA—PsG TECH *c 860-890 850-880 830-860 830-860 810-840 810-840 830-860 840-870 860-900 840-880 850-870 850-880 850-880 830-860 Normalising Hardening cs 860-890 840880 830-860 830-860 810-840 810-840 830-860 840-870 860-900 840-880 850-870 850-880 840-860 840-860 850-880 830-860 820-850 830-850 830-850 830-850 810-830 890-910 390-910 900-940 850-900 800-850 820-860 800-840 Quenching Medium Water or Oil ‘Water or Oil Water or Oil Water or Oil oil oil oll oil Water or Oil Water or Oil Water or Oil oil Water o Oil oil oil oil Water or Oil oil oil oil Air or Oil Oil oil oil oil oil Water or Oil ‘Water or Oil ‘Tempering ite) 550-660 530-760 550-660 530-670 550-660 550~ 660 550-660 550-660 550-660 550-660 550-660 350-700 350-600 550-660 550-720 550-650 550-660 550-660 550—660* ) Depending on iS | octet 150-200 ) hardness up to 660 Above 250 550-700" 550-7008 570-650 580-700 500-700 Above 150 in Oil 130-180 29COLOUR CODING FOR STEEL, 1S — 2649 — 1963 Material Colour oe eee 4S (EN 8, En 9) RED 14Mn 1 § 14 (Free Cutting) YELLOW 40 Ni 2 Ce 1 Mo 28 (En 24) BLUE 15 Ni 2 Ce 1 Mo 15 (En'36) GREY Carbon Too! Steel GREEN High speed steel GREEN & GREY Stainless steel ORANGE Die steel WuITe COLOUR OF HEATED STEELS & THEIR TEMPERATURE Colour of mk Med bea tek mallet” Onde “the (gS ESB ‘Steel Rel’ “Red Red Cherry Red Red oame 2 $8 = Red s & Temp. Range re ae ee) 300 105011501250 oc 6 0770 #50 9001050, 115012801300 COLOUR OF STEEL DURING TEMPERING Puls Straw Yellow Spotted Light’ «Dark Dark Pal Colour ed Grey relow yellow Brown Brown purple purple. Blue Bue Temp. e 20 Da ees ae ais 28S ss 330 —rso rec, PES) 2.10Fert ABCDE = Case hardening APKS — HF-spin hardenin FOHU = HF progressive hardening TUVW — MP (Gingle toothy XGYZ ~ Flame KLMNO = MF APQIR = Nitriding een, DISIGN DATA—Pso TECHSURFACE HARDNESS OBTAINABLE BY FLAME OR INDUCTION HARDENING OF STEELS Designation Rockwell hardness Re x0 s- 9 C35 Mo 75, T= cas ss — 61 css @ T 70 ao 37 Ma 2 9 47 Mn 2 40 Ma 2S 12 35 Mn 2 Mo 28 35 Mn 2 Mo 45 s0cr1 50 Crt 50 Ce 1 V2 40 Cr 1 Mo 28 40Ni3 35. NIL Cr @ 40 Ni I Cr I Mo 15 40 Ni2Cr 1 Mo 8 31 Ni3 Cr 65 Mo 55 4 = 4 os 25 ‘CASE DEPT INCLUDING "GRINDING ALLOWAN! al mm CASE DEPTH ‘AFTER GRINDING | ca eee SELECTION OF HEAT TREATMENT FOR FERROUS COMPONENTS CASE DEPTH , 3 MODULE »mm DESIGN DATA—PSG TECH 2.12 Destx rey Ru > = spoq 2) “use soypos esd xx x x rss 3 xp re 40. sompns.“pouspey x sepa von sand “ou 299 sy wey “9 “io x unnap das $2 och (Smeaae ew ee x F = PEER HUGG gga é SOA UR ase) oe ee pes oe g Nouvorway s ise WESPHL LNAWAINOTA I ss290¥4 & z g SINJNOJWOD SIOWIA AOS INANLVAAL LVSH 4O NOWLOTTESP80 TECH DESIGN DATA: wo 1 cove oss ° ow owt 0096 19 nfasn) 1E 91 6000 so ost ost or owe © so 00 vot ose! ose o z ¥6t © se 000 ror 091 oz o st ozie 076 ® 1 zoo ost ssi sit o #0 ovr ooo ® oo s100 e9r cyt ose o 70 owt one ® or soo re wt os, os ors 900 0096 10 soo st ont os os ow ve 0096 oro. soo 68 It os 0s oe cu om $2 900 zs % os 0s ou on 0096 Izow1s90¢ oC Ce! Aousye won funeado —-apoig ONPIGAWAL NOLLIAGNI AAISSINDONA WOd VIVE ONULVAIEO 2.14mec COMPOSITION OF Ingredients, % by weight Remarks Type é & 8 ae = ; me Ds ss oe ji 0 10 eee i %” 0 : a ois 0-85 v 10-15 0-85 reer aa LiguD NrTRuDING MATERIAL — ? ser re Ben tow sey vee © 1 ses 5 i Die at w 180 S356 5 5 Res ot 3 ° 8 3 ess a meee © 12 “6 : i" oo Sphere, mallsble & prey 120 20 ss $ COMPOSITION OF SALTS BY WIEGHT FOR NITRIDING AT 565 °C for general Purpose for tool steels %Sodium salt © — 0° NaCN—30%: Nay ©0y or Ks COs—25%max + Potassium salt 40 — 30% moisture — 2%; other activators — 4% man, KCI — remainder Constituents NaCN = 96.5%; Nox CO, — 2.5% +KCN — 96%; Ks CO, — 0.6%; NaCNo — 057, KCNO — 0.75%; KeI— 05 DESIGN DATA—PSG TECH 2.15PROCESSES OF HEAT-TREATMENT FOR ALUMINIUM ALLOY CASTINGS Hardening ‘Age-hardening Heat-treating Alloy, 2 = = for annealing Brivell process “Temp Holding «Temp. Holding” Hardness SC” time hours Gime, hours Ageing S5i, 153.5 Cu, 02-08ME 80 5 70 swlthos 030i Min preliminary “te. — 8 18 70 ardening Si, 1.5 Cu, 05 Me 180 6 SSi, 2Cu, 0.20.8 Me. 290 65 02-08'Mo Annealing 5Si, 2-3 Ce 3 290 3 4s 4-5.cu sis 10-15, = © Hardening 95 — 115 Me “0 1s-20 ts @ 7Si, 02-04 Mg 35 0 7Si, 10-14 Za, 0.1-03Mg SIS 220 24 9s Hardening & SSi, 2 Cu, 02-08 Me, sis 4-6 130 s % 03-08 Nn partial ‘cing SSi, 1.5 Cu, 05 Me cen og 180 70 sis S180 7 7Si, 02-04 Mg aber} 190 La o Hardening and 9Si, 0.1703 Me, 3s 26 us 1s full ageing 035 05'Ma Hardening and 9-1 cu sis S10 4 100 stabilising SSi, 2Cu, 020.8 Mg, Boas 230 5 0 0208 Ma Hardening and SSi, 15 Cu, 0.5 Mg m4 230 s 6s and tempering SSi, 2 Cu, 02 — 08 Me so $6 20 3 65 02'— 08 Mn 2.16 DESIGN DATA—PSG TECHTYPICAL STRESS RELIEVING TEMPERATURES FOR WROUGHT COPPER ALLOYS . Brae eS Aegan tae ALLOYS a 3 ae ig aeae gS 82 3h gs ef g6 Bo sa_05 Sa 38 cE fa dz ELIEVING, STRESS Ru Goal 2051) Cn %oeg. ney) Pg ae Pa eat Te for one ho ar holding DEFECTS IN HEAT-TREATMENT OF STEELS Low ductility, the eaets re being Course-grained Cow ductlty ang Parcculrly, in Strength tight Teacture High hardness Chiet cause Measures to prevent and correct the defect ‘Ammealing and Normal ing Defects of Steels Underheat, Repeat annealing or normalising Anneting temp at normal temperatures below that required or insufficient holding Qvetheat. Considerable over- Repeat _anncaling or normalising at normal tem- heating or ex ssive holding perature. "In. case. of considerable overheating tse double annealing, the first one at a temperature by S0™150°C above’ the normal Qverheat, Heating of steel No in an oxidising atmosphere. at high temperatures, in the proximity of the melting point ay Excessive cooling rite Repeat annealing at the required cooling rate 2 Defects in Annealing of Tool and High-Speed Steels High hardness 1 Underhest. Repeat annealing at a requisite temperature ang 2 Excesive cooling rat in normal follow arity the prescved cooling schedehe annealing oF insufficient holding or temper at high teonperature, ins thermal annealing Carbide lattice Heating above Normalising or hardening with subsequent temper- An Jing at 670-=700°C, holding time not less than? brs Cracking Stresses caused by changes in irreparable defect. Preventive measures, volume arising from trans formation of austenite to martensite at temperatures J. Whenever possible use step-hardening, as well below’ 250°C as intermittent hardening’ in two. guenching edi 2 Avoid manufacturing parts with acute angles sharp changes in section; when this it un avoidable, use only alloy’ steel 3. Nowater should be present inthe oil quenching tank DESIGN DATA—PsG TECH 2.17FITS AND TOLERANCESSPECIFIED ROUGHNESS TO BE Geraned 8Y MACHINING vs SYMBOL: SYMBOLS DESIGN DATA—psc TECHOBTAINABLE RANGE OF SURFACE ROUGHNESS, R,” IN MICRONS Manufacturing Proses ith Normally Rowing pittally ip ett 2s u3— 2 &permanet mould ie—6a v Die casting 08 — 32 Fo rewe M632 322 2 pansion oa — 08 os — 63 3 £ _Roling o4 — 08 og 32 | Flame Got 3% | Hack Sew Cut Hak saw Cut «9 2 ~ pasaw, Coppiag 22-30 3 rium os —16 Ls — 125 Emery Polish o1—04 oa — 16 6-32 Shot Blas 1632 32 Be Tumbling 02-125 g 5G Ateashe Bet o4— 63 BE Fite Whee truiog 02 — 08 on Cloth butng co 00s 00s — 04 SHELL MILLING 16-32 3235 20 DRILLING 3263 «a3 PLANING & SHAPING Lé— 12s FACE MILLING ae 16 — 123 Rs TURNING ae 1s a9 3 aoric Ee is 0 3 REAMING oa — 08 os 63 — 2s 3 CYL oRINDING oms—04 a 3263 & CeNTRELESS GRINDING 00s — 0 oa 2 INTERNAL GRINDING 0.025 4 04 SURFACE GRINDING oa BROACHING ox SUPER FINISHING Ne HONING ou LAPPING os MILLING, SPIRAL BEVEL Ta 32 carr aes 2 MiLtinc win FoRM CUTTER 16 —32 32 eee E — Honsine og — 32 32 — 2s—9 2 suarinc o4 — 16 Ls — 2s — 280 Z PLANING 04 —16 Le ae 3 suave o4 —08 on w% GRINDING, Criss Cros oa — 08 08 — 16 a GRINDING O1— O04 04 — 08 - LAPPING 0.05 — 02 0.2 — 08 x2 DESIGN DATA—PSG TECH3 33 2 EF gi if SE rs Hiss teen ee SSN] | SYSTEM OF BASIC HOLE RUNNING AND SLIDING FITS Combination of eemioation ol Quality of ft Typical uses HG g5 Fine ) Small clesrance-sed in precision equipment under H7 6 Normal $ Precision _—_very light load-Beatings for accurate link work Hi g7Coane and for piston and slide valves-Also sed fo spigot or location fis Widely used as grease or oil lubricated bearings Close running having low temperature differences-bearings for 5 gear shafts, small eletrie motor shafts and. pump Normal running HB d8 Fine Loose running H9 d9 Coarse Hi 08 ; ns st Fine H8 d9 Normal j | H9 a9 | jn | J Slack running or mm poston ii i aan Mil Used for properly lubricated bearings with appreciable clearance, Finer grades for high speeds and heavy loads-Turbo generator and large electric motor bearings. For plummer block bearings and loose pulleys, Large clearance-not widely used. 34 DESIGN DATA—PSG TECHLOCATIONAL AND ASSEMBLY FITS Combination of — Quality of Holand Shaft Be 6 ns heme Hs vein | wT hs come | *HT h7 location i HB h7 Norcal | ons bs Tocation Ho hs Lote Hy nv ioerton | ani sack | SHUEY asenbiy | °H8 bo Positional | ss 29 (etme Typical uses Alll these fits are widely used for non running parts, for normal location and spigot fits—In finer grades, used as a Precision sliding fit * Preferred combinations. HOLE SHAFT SHAFT ‘Transit Fite KK SYSTEM OF BASIC HOLE ZERO LINE SHAFT. SSS HOLE Interference Fits BASIC SIZE TRANSITION AND INTERFERENCE FITS ation of Qualiy of ie and Sha Hs Fae B76 Norma ? Cleaner HB j7 Coarse H6 ks Fine HT k6 Normal True transition H8 k7 Coarse H6 ms Fine H7 m6 Normal} Interference H8 m7 Coarse § ‘Fansition Typical uses Very small clearance is obtained wed for fits where a Permissible - coupling spigots and nped to steel hubs. slight interference recesses, gear rings Fits averaging no clearance where slight interference can be tolerated, with the object of eliminating vibration - ball bearing races of light duty Fits averaging slight interference-used for ball bearing races of medium duty. DESIGN DATA—PsG TecH EZZZZZZA_ ZERO LINETRANSITION AND INTERFERENCE FITS (Contd) Combination of foe ond sett Quality off Typical uses 6 Fine Light pres for nonferrous parts which can be dismantled when Ht pe Nomi J Pres Ligh Efi bushes pres ft for Seeh, cat irom or brass 10 Ta Sscmblee bush in & Ber H6 r5 Fine Medium drive St for ferous part and light drive ft for nom HG 6 Novmat } Drive ote pare that can be dane HG 65 Fine Permanent. or semi permanent assemblies of steel and cast iron HY 86 Normal itr zonsldcrable gripping force-collas pressed on to shafts, valve eatingr ete. For light alloys this ives a pres fit H6 US Fine Force or High interference ft. A. thorough investigation into the degree H7 U6 Normal} sink it Of grip and the stresses in the part must be made For Grades § to 16, standard tolerance unit i, is i = 045 9D + 0.001 D in microns ; D in mm. m7 80 | $69 SEAR AE | a Te Fry 335 1g He lie ook! NO eg see Wo oe oe ee = . € [S363 eet Values 7 mw si i toh Took 25tk okt toms IBS aaa ~ Flasks ot MANUFACTURING PROCESS USED e Holes leskea HS FINE BORING, FINE GRINDING, HONING aay 6 FINE BORING, HONING, HAND REAMING ese HT INT. GRINDING, BROACHING, REAMING ne He BORING, MACHINE REAMING ages 19 BORING & REAMING fs HI0 Not for diameter fits; used for milled widths, drilled holes. s HY Not used in fits; punching, coarse drilling drawn recesses. a" mos esig DESIGN DATA—PSG TECH. 3.6MLO DUOEAU] —SUONDHL Y| $22uDI8]01 +06 ON-N 109-9 aon a Oa= [OIF] OB] I=] 08>] al oo- | oo- | _oo- | o0-|00-| 00-| 00-| 9 ‘oz [98> oe= Nb 90 | _90- za o0- te 90 z= oo= | 90-| 60-| oo-| =|" 91) t=] 60=| so- | 90-[N ae eo oo- gr | 60~ 0-| 00-| o0-| 91% =| so] 90= TH 2/632] 68: 3921" o|se Cae fo-|" ol = =| zo-| 9 | 9 30-[ ag DESIGN DATA—Pso TECH 3 TECHuxt = wwnigg;0* wos} suo1ojW_u se2uaueteL ‘05 ON-N ‘00-9 _-8PN 2 Bers oie] os Oa Taig er | We] es eee & s9z+ |seze| Siz +] 361+] i Scslies | ose] oye | Lee 5 Digs) ost sf oct] ‘Oselere | tye] eee faze z azz sate] 02 [ez | oss] tos | ses ; 3914 74 ye] tye [eee « i a4] tzs|_e_ [ies] oe é tes [oepece a oe a 5 a a & | wus “305 seiewor ce SSONVEFIOL JO FIGvL udaz+ ozs z+ [t+ ye loco DESIGN DATA—PSG TECH S82) Sel Soe | S82 | 2321 See| Set] St malt swuinro vor, — suoryu 4 SeDuoumOL 108 ON-N 00-9ssva 70H NVAN BAL Lng NOUVIEWA ONY Lid N¥aH DESIGN DATA~PSG TECH 0 3.1PaMoND 2q 0} any fow sa2uDI—}0; aKOgD at 2 poob ui yuauidinbs 40 $s0)2 poo6 40} 21D P 0} auIyIOW ayy UO pasn ‘219 spoay Bu ‘siuauidinbe {apni uodn yuapuedap aio s92u019I0) 259UL nO )9Z0.0 40 YONEDA yoouJSUIDIP Jo 22u0N2}) SsoupUNOY y # ‘310g oui win) ould Dipue ssepunk> z ea TopunAS Jo e20jins jo WISUR wishuni so pessaaG | BONVETIOL JO 430HO S35S3908d ONINIHOVN ONY SSONVUSTION AML3WOI9 NIIM13G NOUYIZ4 wurtooo=Tan Ald NY3W 3HL 1NO@V NOUWIEWA ONY 4 2wanx® au0 yo aounioay> yous O sani6 er or- ws sm 14 NWSW 3. DESIGN DATA—PSG TECHPREFERRED BASIC & DESIGN SIZES ANGULAR DIMENSIONS unit: degree Prone PREFERRED ANGLES parlor cat Teo 8 aa UNGAR DMENSIONS it __HOLE BASS SHAFT BASS STANDARD TOLERANCES FOR GEOMETRY x T PRORITY ‘PRIORITY {FOR LINEAR DIMENSIONS —_unitmm isa peee ee (ala pmsl [eames [oe Sr 7 S60] 12] seo]seoa| uso] [re | 50 o.0012| 0012 | on2 | 12 16 690| 20| ssolazoo| isso] | 25 | &° | | 0.0016 | 0.016 | 016 | 16 3 ol a2 seelcee| see] | £2. | 23 | Jose] cae} cr | o2e | acl B40| 45 | ca] 00] wo] [ke ol aap oamrs|oms | 02s | 25 60 1000] 70|150| | 1950] | 250 | 22-0 900% | 0-0040| 0.040 | o40 | 40 so wool 20 lena] |e] [aon [ee | | |eano|omo | os0 | s0 Beesad iss [aoa [£22 [25 | leans] omo| esto | oso | 0 | 120 woo] 1301200} - |s200) {0008 | o.0080| 0.000 | 080 | 00 | "eo wou} 30 [iso] |3s00| mean oueagons tes ied 170 [00] |2700| peepee enn 200 2204) 21-0 |1900 4100 7 ae | FOR TAPERS rien Be reetissfnssl = \uaslafer let z Tegal Saat 250 2000|26.0|2300| | «600 ‘ pelle ls j ee Toalseo aol lawel | we | a | [8% | | oom oome| cow] 320 3600] 340 |2000| | ie en a 26.0 400-0] 38-0 |2700 30 2 ore | cones | o-0080 | Os0 400. 450-0| 42.0 |3000 Fa Jo | 450 5000) 480 |2400 m ees a Le a PS ee a Fs srMgois FOR GEOMETRY OF FORM & POSITIN [3 cumerenses macs] | § eamarenencs | sweats ® romess 1 3 [Pemrenocuanry i 3 [encuanme On] | 3 eewen el } = |: 2 § | coneenmmary ox Gonsaure © I “ peal ea 3.12 DESIGN DATA—Ps6 TECH }ROLLING ELEMENT BEARINGSBALL AND ROLLER BEARINGS Designation | Application Type and Figure cove ball bearing Can carry considerable thrust load apar from radial load—high speed Self aligning ball bearing Minor angula not affect *For heavy axial contact ball bearing || Doub! .ds with heavy th Sphe Af aligning—for (aa nsiderable ax Sy Fa Cylindrical rolter bearing For heavy radial loads at hi : permit slight axial displacement Taper roll 8 ‘ nd a ‘ Sing ball bearing 0x cone direction onl eo D y 9 axial load: ° ns si Fork < 1. b speed—self *Note: Always adjusted towards another bearing capable of carrying axial load in the opposite direction DESIGN DATA ~PSG TECH zsBALL AND ROLLER BEARINGS Nomenclature : radial load, kef mr = million revolutions a axial load, kef L_ = required life of the bearing in million revolutions basic dynamic capacity, ket Lyo — Life of the bearing for 90% survival basic static capacity 10 d static capacity, kef mee parse cee p — probability of survival aoe be, Pi — Probability of survival for 90% or 0.9 radial factor — median life based on 50% survival thrust factor F,, — cubic mean load (axial or radial) s Phebe et Rotary M/e with no impact Li-15 t — time Reciprocating m/e 13-19 Mic with pronounced impact, hammer ills etc 16-4 Equivalent Load: P = (XF,+YF)S Dynamic Capacity : c-( Ly Lyo=! mr, 3 for ball bearings (0/3 for roller bearings CIP may also be obtained direct from the charts on pages 185 and 186 Probability of survival: L Ja ie)! te L = required life of bearing in me Lo ~ Lin (imo) L',p — ealeulated life of selected bearing, for the given load, for 90% survival & In (1/Pyg)=In (1/0.9)=0.1053 b= 1,17 for a median life=SLig b = 1.34 for a median life=4.08 Lyp (for deep groove ball bearings) For a system having x bearings each having the probability as p, the survival probability pF Parson Cubie mean load: (F, Fa-[E a ye (revolutions varying) (time varying) Decrease in carrying capacity at high temperatu Bearing temp. °C 150 175 200 225 250 Decrease in cay 0% 15% 25% 389% 40% 42 DESIGN DATA—PSG TECH