16
A TEXTBOOK OF
MANUFACTURING TECHNOLOGY
(Manufacturing Processes)
By the Same Author:
� Thermal Engineering� Engineering Thermodynamics
� Applied Thermodynamics� Internal Combustion Engines� Automobile Engineering� Power Plant Engineering
� Elements of Mechanical Engineering� Steam Tables and Mollier Diagram (SI Units)
LAXMI PUBLICALAXMI PUBLICALAXMI PUBLICALAXMI PUBLICALAXMI PUBLICATITITITITIOOOOONS (P) LNS (P) LNS (P) LNS (P) LNS (P) LTDTDTDTDTD(An ISO 9001:2008 Company)
BENGALURU � CHENNAI � COCHIN � GUWAHATI � HYDERABADJALANDHAR � KOLKATA � LUCKNOW � MUMBAI � RANCHI � NEW DELHI
BOSTON (USA) � ACCRA (GHANA) � NAIROBI (KENYA)
A TEXTBOOK OF
MANUFACTURING TECHNOLOGY
(Manufacturing Processes)
For B.E./ B.Tech., A.M.I.E.-Section B, and Competitive Examinations
By
Er. R.K. RAJPUTM.E. (Hons.), Gold Medallist; Grad. (Mech. Engg. & Elect. Engg.);
M.I.E. (India); M.S.E.S.I.; M.I.S.T.E.; C.E. (India)Recipient of:
‘‘Best Teacher (Academic) Award’’‘‘Distinguished Author Award’’
‘‘Jawahar Lal Nehru Memorial Gold Medal’’for an outstanding research paper
(Institution of Engineers–India)Principal (Formerly):
� Thapar Polytechnic College;
� Punjab College of Information Technology,PATIALA
A TEXTBOOK OF MANUFACTURING TECHNOLOGY
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First Edition: 2007; Second Edition : 2015ISBN 978-81-318-0244-1
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Bran
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Contents
Chapter Pages
1. CONCEPT OF MANUFACTURING ... 1–38
1.1. Introduction ... 11.2. Manufacturing System ... 1
1.2.1. General aspects ... 11.2.2. Classification of manufacturing processes ... 21.2.3. Selection of a manufacturing process ... 31.2.4. Process planning ... 41.2.5. Analysis of manufacturing system ... 4
1.3. Types of Production ... 51.4. Control Systems ... 6
1.4.1. Introduction ... 61.4.2. System ... 61.4.3. Control system ... 61.4.4. Classification of control systems ... 71.4.5. Open-loop control systems (Non-feedback systems) ... 81.4.6. Closed-loop control system (Feedback control system) ... 91.4.7. Automatic control systems ... 10
1.5. Organisation, Administration and Management ... 111.6. Plant Organisation ... 111.7. Scientific Management ... 15
1.7.1. Definition ... 151.7.2. Principles ... 151.7.3. Aims ... 15
1.8. Functions of Management ... 161.9. Plant Location ... 161.10. Plant Layout ... 161.11. Production, Planning and Control (PPC) ... 20
1.11.1. Definitions ... 201.11.2. Functions of PPC ... 201.11.3. Advantages of production control ... 201.11.4. Constituents of production control ... 20
Questions with Answers ... 23
Highlights ... 34
Objective Type Questions ... 35
Theoretical Questions ... 37
( v )
Chapter Pages
( vi )
2. CASTING PROCESSES ... 39–139
2.1. Introduction ... 392.2. Patterns ... 40
2.2.1. Definition ... 402.2.2. Requirements of a good pattern ... 402.2.3. Pattern materials ... 402.2.4. Types of patterns ... 422.2.5. Pattern allowances ... 46
2.3. Mould Making ... 482.3.1. General aspects ... 482.3.2. Types of moulds ... 492.3.3. Moulding processes ... 492.3.4. Types of sand moulding ... 50
2.4. Core ... 522.4.1. Core making ... 532.4.2. Types of cores ... 532.4.3. Core prints ... 562.4.4. Core box ... 56
2.5. Moulding Sand ... 572.5.1. Properties of moulding sand ... 572.5.2. Types of moulding sand ... 582.5.3. Composition of the green sand ... 592.5.4. Sand testing ... 60
2.6. Melting Equipment ... 632.6.1. Crucible furnace ... 632.6.2. Reverberatory or air furnace ... 642.6.3. Open hearth furnace ... 652.6.4. Electric furnace ... 652.6.5. Cupola furnace ... 67
2.7. Melting and Pouring ... 722.7.1. Melting ... 722.7.2. Pouring ... 73
2.8. Gating System ... 742.9. Cooling and Solidification ... 822.10. Casting ... 912.11. Advantages and Disadvantages of Casting Process ... 912.12. Preparation of a Casting ... 922.13. Basic Rules for Good Casting Design ... 922.14. Casting Processes ... 93
2.14.1. Sand casting ... 932.14.2. Shell-mould casting ... 942.14.3. Plaster-mould casting ... 952.14.4. Ceramic-mould casting ... 962.14.5. Vacuum casting ... 972.14.6. Evaporative-pattern casting (lost foam) ... 972.14.7. Investment casting
(precision casting process or lost wax casting process) ... 98
( vii )
2.14.8. Slush casting ... 1002.14.9. Pressure casting ... 1002.14.10. Die casting ... 1002.14.11. Centrifugal casting ... 1022.14.12. Squeeze casting ... 1042.14.13. Semisolid metal forming ... 1042.14.14. Continuous casting ... 104
2.15. Defects in Castings ... 1052.16. Cleaning of Castings ... 1082.17. Inspection of Castings ... 110
Questions with Answers ... 110Highlights ... 136Objective Type Questions ... 137Theoretical Questions ... 138
3. METAL FORMING PROCESSES ... 140–218
3.1. Introduction ... 1403.2. Cold and Hot Working ... 141
3.2.1. Cold working ... 1413.2.2. Hot working ... 1423.2.3. Comparison of cold working and hot working processes ... 144
3.3. Rolling ... 1453.3.1. Principle and mechanism of rolling ... 1453.3.2. Rolling stand arrangement ... 1493.3.3. Defects in rolling ... 151
3.4. Forging ... 1523.4.1. Introduction ... 1523.4.2. Advantages and disadvantages of forging ... 1523.4.3. Classification of forging ... 1523.4.4. Basic categories of forging ... 1563.4.5. Methods of forging ... 1583.4.6. Other forging processes ... 1613.4.7. Defects in forging ... 1653.4.8. Cleaning and finishing of forgings ... 1663.4.9. Heat treatment of forgings ... 1663.4.10. Design considerations ... 166
3.5. Extrusion ... 1673.5.1. Introduction ... 1673.5.2. Advantages, limitations, and applications of extrusion process ... 1683.5.3. Classification of extrusion processes ... 1683.5.4. Hot extrusion processes ... 1693.5.5. Cold extrusion processes ... 1703.5.6. Extrusion force ... 1723.5.7. Extrusion equipment ... 1733.5.8. Extrusion defects ... 173
Chapter Pages
( viii )
3.6. Wire Drawing ... 1743.7. Tube Drawing ... 1763.8. Tube Making (By rotary piercing) ... 1773.9. Metal Stamping and Forming ... 177
3.9.1. Introduction ... 1773.9.2. Bending ... 1783.9.3. Deep drawing ... 1793.9.4. Stretch forming ... 1803.9.5. Metal spinning ... 1803.9.6. Shear forming and flow forming ... 1823.9.7. Blanking ... 1833.9.8. Piercing ... 1843.9.9. Embossing and coining ... 1843.9.10. Roll forming ... 1853.9.11. Rubber press forming ... 1853.9.12. Hydromechanical forming ... 1863.9.13. Defects in sheet metal formed parts ... 186
3.10. Shot Peening ... 1863.11. Types of Dies ... 187
3.11.1. Classification of dies ... 1873.11.2. Causes of failure of dies in metal working operations ... 189
3.12. Presses ... 1893.12.1. Classification of presses ... 1893.12.2. Cutting forces and energy in press work ... 192
3.13. Comparison of Metal Forming Processes ... 192Questions with Answers ... 194Highlights ... 216Objective Type Questions ... 216Theoretical Questions ... 217
4. POWDER METALLURGY ... 219–232
4.1. Definition ... 2194.2. Advantages, Disadvantages/Limitations of Powder Metallurgy ... 2194.3. Applications of Powder Metallurgy ... 2204.4. Manufacture of Parts by Powder Metallurgy ... 220
4.4.1. Production of metal powders ... 2204.4.2. Blending of metal powders ... 2214.4.3. Pressing or compaction of metal powders ... 2224.4.4. Sintering ... 2234.4.5. Finishing operations ... 225
4.5. Design Considerations for Powder Metallurgy ... 225Questions with Answers ... 226Highlights ... 231Objective Type Questions ... 231Theoretical Questions ... 231
Chapter Pages
Chapter Pages
( ix )
5. PROCESSING OF PLASTICS ... 233–259
5.1. Introduction to Plastics ... 2335.1.1. Definition of plastic ... 2335.1.2. Classification of plastics ... 2335.1.3. Characteristics/properties of plastics ... 2355.1.4. Compounding materials ... 2365.1.5. Fiber glass reinforced plastics ... 2375.1.6. Trade names and typical applications of
some important plastics ... 2375.2. Processing of Plastics ... 238
5.2.1. General aspects ... 2385.2.2. Plastic processing methods ... 2395.2.3. Compression moulding ... 2395.2.4. Transfer moulding ... 2405.2.5. Injection moulding ... 2415.2.6. Expandable bead moulding ... 2425.2.7. Rotomoulding ... 2425.2.8. Blow moulding ... 2435.2.9. Extrusion ... 2445.2.10. Thermoforming ... 2455.2.11. Calendering ... 2455.2.12. Casting ... 246
5.3. Machining of Plastics ... 2465.4. Joining of Thermoplastics ... 2485.5. Plastic Design Rules ... 249
Questions with Answers ... 250Highlights ... 258Objective Type Questions ... 258Theoretical Questions ... 259
6. CERAMIC AND COMPOSITE MATERIALS—THEIR STRUCTURE,PROPERTIES AND PROCESSING ... 260–291
6.1. Introduction to Ceramic Materials ... 2606.2. Classification of Ceramics ... 2606.3. Advantages of Ceramic Materials ... 2616.4. Applications of Ceramics ... 2626.5. Properties of Ceramic Materials ... 2626.6. Structure of Crystalline Ceramics ... 2646.7. Silicate Structures ... 265
6.7.1. Types of silicate structures ... 2656.8. Polymorphism ... 2676.9. Glass ... 268
6.9.1. Definition and structure ... 2686.9.2. Constituents of glass and their functions ... 2686.9.3. Properties of glass ... 2696.9.4. Glass furnaces ... 271
Chapter Pages
( x )
6.9.5. Fabrication of glass ... 2726.9.6. Classification of glass ... 2736.9.7. Uses of glass ... 2766.9.8. The glass industry in India ... 276
6.10. Advanced Ceramics ... 2766.11. Processing of Ceramics ... 278
6.11.1. General aspects ... 2786.11.2. Shaping processes ... 2786.11.3. Drying and firing ... 2796.11.4. Finishing operations ... 279
6.12. Design Considerations for Ceramics ... 2796.13. Introduction to Composite Materials ... 2806.14. Classification ... 281
6.14.1. Particle-reinforced composite ... 2816.14.2. Fibre-reinforced composites ... 2826.14.3. Structural composites ... 283
6.15. Production of Composite Structures ... 284Questions with Answers ... 285Highlights ... 289Objective Type Questions ... 289Theoretical Questions ... 290
7. WELDING AND ALLIED PROCESSES ... 292–361
7.1. Introduction ... 2927.2. Advantages, Disadvantages and Applications of Welding ... 2937.3. Classification of Welding Processes ... 2947.4. Forge Welding ... 2957.5. Resistance Electric Welding ... 296
7.5.1. General aspects ... 2967.5.2. Resistance spot welding ... 2977.5.3. Resistance seam welding ... 2987.5.4. Resistance projection welding ... 2997.5.5. Resistance butt welding ... 299
7.6. Gas Welding ... 3017.6.1. Fusion welding—General aspects ... 3017.6.2. Advantages and disadvantages of gas welding ... 3017.6.3. Applications of gas welding ... 3027.6.4. Oxy-acetylene welding ... 302
7.7. Electric Arc Welding ... 3067.7.1. Introduction ... 3067.7.2. Advantages and limitations ... 3067.7.3. Metallic arc welding ... 3067.7.4. Carbon arc welding ... 3077.7.5. Atomic hydrogen welding ... 3087.7.6. Shielded arc welding ... 3087.7.7. Arc blow ... 309
Chapter Pages
( xi )
7.7.8. Comparison between A.C. and D.C. arc welding ... 3097.7.9. Types of welded joints ... 310
7.8. Thermit Welding ... 3137.9. Tungsten Inert-Gas (TIG) Welding ... 3147.10. Metal Inert-Gas (MIG) Welding ... 314
7.10.1. Differences between TIG and MIG welding processes ... 3157.11. Submerged Arc Welding ... 3157.12. Electro-slag and Electro-gas Welding ... 317
7.12.1. Electro-slag welding ... 3177.12.2. Electro-gas welding ... 317
7.13. Electron-beam Welding ... 3187.14. Ultrasonic Welding ... 3197.15. Plasma Arc Welding ... 3207.16. Laser Beam Welding ... 3207.17. Friction Welding ... 3227.18. Explosive Welding ... 3237.19. Diffusion Welding ... 3247.20. Induction Welding ... 3247.21. Cold Welding ... 3257.22. Stud-arc Welding ... 3257.23. Hydrodynamic Welding ... 3267.24. Under-water Welding ... 3267.25. Oxy-acetylene Torch Cutting ... 3267.26. Solid/Liquid-State Bonding–Soldering and Brazing ... 3267.27. Soldering ... 327
7.27.1. Definition ... 3277.27.2. Classification of soldering methods ... 3277.27.3. Types of solder ... 3287.27.4. Selection of solder ... 3287.27.5. Flux or soldering fluid ... 3287.27.6. Soldering equipment ... 3297.27.7. Soldering procedure ... 3297.27.8. Characteristics of a good joint ... 3297.27.9. Important tips for effective soldering operation ... 3307.27.10. Advantages of soldering ... 3307.27.11. Applications of soldering ... 3307.27.12. Types of soldered joints ... 331
7.28. Brazing ... 3317.28.1. Introduction ... 3317.28.2. Fluxes ... 3317.28.3. Brazing equipment ... 3327.28.4. Brazing methods ... 3327.28.5. Brazing procedure ... 3327.28.6. Advantages and limitations of brazing ... 3337.28.7. Applications of brazing ... 3337.28.8. Silver soldering (or silver brazing) ... 3337.28.9. Comparison between soldering and brazing ... 334
Chapter Pages
( xii )
7.29. Electrodes ... 3347.29.1. Electrode materials ... 3347.29.2. Electrode coatings ... 3347.29.3. Electrode’s designation ... 3357.29.4. Typical data on use of “mild steel electrodes” ... 335
7.30. Welding of Various Metals ... 3367.31. Rebuilding ... 3377.32. Hard Facing ... 3387.33. Characteristics of Good Weld ... 3387.34. Defects in Welds ... 3397.35. Weldability ... 3407.36. Testing of Welded Joints ... 3417.37. Effect of Welding on the Grain Size of the Metal ... 3417.38. Principles of Welding Design ... 3427.39. Comparison of Welding and Allied Process ... 342
Worked Examples ... 344Questions with Answers ... 345Highlights ... 355Objective Type Questions ... 355Theoretical Questions ... 360
8. METAL CUTTING ... 362–419
8.1. Introduction ... 3628.2. Chip Formation ... 3628.3. Types of Chips ... 3638.4. Cutting Tools ... 364
8.4.1. Classification ... 3648.4.2. Single point cutting tool ... 3658.4.3. Tool elements and tool angles ... 3658.4.4. Tool signature (or tool designation) ... 367
8.5. Orthogonal and Oblique Cutting ... 3688.6. Chip Control ... 3698.7. Force of a Single-point Tool ... 3708.8. Mechanics of Metal Cutting ... 371
8.8.1. Shear zone, shear plane and shear angle ... 3718.8.2. Chip thickness ratio ... 3728.8.3. Velocity relationship in orthogonal cutting ... 3738.8.4. Forces on the chip (Merchant’s analysis) ... 3748.8.5. Stress and strain on the chip ... 3768.8.6. Work done during metal cutting and specific cutting energy ... 3788.8.7. Theories on mechanics of metal cutting ... 378
8.9. Friction in Metal Cutting ... 3898.10. Thermal Aspects of Metal Cutting ... 390
8.10.1. General aspects ... 3908.10.2. Factors affecting temperature ... 3918.10.3. Temperature distribution in metal cutting ... 3918.10.4. Measurement of chip-tool interface temperature ... 392
Chapter Pages
( xiii )
8.11. Tool Wear and Failure ... 3938.11.1. Tool wear ... 3938.11.2. Tool failure ... 394
8.12. Tool Life ... 3968.13. Cutting Speed, Feed and Depth of Cut ... 4008.14. Machinability ... 4018.15. Cutting Fluids ... 403
8.15.1. Functions of cutting fluids ... 4038.15.2. Requirements of a cutting fluid ... 4048.15.3. Types of cutting fluids ... 404
8.16. Cutting Tool Materials ... 4058.16.1. Characteristics of an ideal cutting-tool material ... 4058.16.2. Types of tool materials ... 405Questions with Answers ... 409Highlights ... 415Objective Type Questions ... 416Theoretical Questions ... 417Unsolved Examples ... 418
9. MACHINE TOOLS AND MACHINING PROCESSES ... 420–578
9.1. Introduction ... 4219.1.1. Machining processes ... 4219.1.2. Machine tools ... 423
9.2. Centre/Engine Lathe ... 4249.2.1. Introduction ... 4249.2.2. Working principle ... 4259.2.3. Parts of lathe ... 4259.2.4. Size and specifications of lathe ... 4279.2.5. Types of lathe ... 4289.2.6. Lathe tools ... 4299.2.7. Lathe operations ... 4309.2.8. Lathe accessories ... 4389.2.9. Lathe attachments ... 4419.2.10. Cutting speed, feed and depth of cut ... 4429.2.11. Material removal rate (MRR) ... 4439.2.12. Machining time ... 4449.2.13. Power required in turning ... 4459.2.14. Thread cutting ... 4509.2.15. Eccentric turning ... 455
9.3. Turret and Capstan Lathes ... 4559.3.1. Introduction ... 4559.3.2. Limitations of a centre lathe ... 4559.3.3. Differences between a turret lathe and a centre lathe ... 4569.3.4. Comparison of turret lathe and capstan lathe ... 4579.3.5. Main parts of a turret or capstan lathe ... 4609.3.6. Types of turret lathes ... 461
Chapter Pages
( xiv )
9.3.7. Size and specifications of turret lathe ... 4639.3.8. Common tools and attachments used on turret
and capstan lathes ... 4639.3.9. Turret lathe operations ... 4649.3.10. Turret lathe tooling layout ... 464
9.4. Automatic Lathes ... 4659.4.1. Introduction ... 4659.4.2. Classification of automatic lathes ... 4669.4.3. Automatic vertical multistation lathe ... 4679.4.4. Automatic screw machines ... 468
9.5. Shaping Machine (Shaper) ... 4699.5.1. Introduction—principle of working ... 4699.5.2. Advantages, limitations, and applications of shapers ... 4709.5.3. Classification of shapers ... 4719.5.4. Principal parts of a shaper ... 4729.5.5. Specifications of a shaper ... 4739.5.6. Quick return mechanism in a shaper ... 4739.5.7. Shaper work holding devices ... 4769.5.8. Operations performed ... 4769.5.9. Cutting tools and other tools used in shaper work ... 4779.5.10. Cutting speed, feed and depth of cut ... 4789.5.11. Machining time ... 4799.5.12. Material removal rate ... 480
9.6. Slotting Machine (Slotter) ... 4829.6.1. Introduction ... 4829.6.2. Main parts of a slotter ... 4829.6.3. Size and specifications ... 4839.6.4. Slotter drive mechanisms ... 4839.6.5. Types of slotters ... 4839.6.6. Work holding devices ... 4839.6.7. Slotter cutting tools ... 4839.6.8. Slotter operations ... 483
9.7. Planing Machine (Planer) ... 4849.7.1. Introduction ... 4849.7.2. Principle of working—planing operation ... 4859.7.3. Comparison between planer and shaper ... 4869.7.4. Types of planers ... 4869.7.5. Principal parts of a planer ... 4869.7.6. Size of a planer ... 4879.7.7. Planer driving and feed mechanisms ... 4879.7.8. Standard clamping devices ... 4889.7.9. Planer tools ... 4889.7.10. Planer operations ... 4899.7.11. Cutting speed, feed and depth of cut ... 4899.7.12. Machining time and material removal rate ... 490
9.8. Drilling Machines ... 4909.8.1. Introduction ... 490
A Textbook Of ManufacturingTechnology (Manufacturing Processes)
Publisher : Laxmi Publications ISBN : 9788131802441 Author : R K Rajput
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