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PRODUCTION TECHNOLOGY VOL. I

PT_9788185594781

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Length170 mm
Thickness15 mm
Height240 mm
Weight465
AuthorK. G. Aswani
Pages336 + 16 = 352
BindingPaperback
ISBN9788185594781
SizeCrown
Edition1st

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Prodyction_Technology_Vol_I

PRODUCTION TECHNOLOGY VOL. I[Manufacturing processes and materials]K. G. AswaniEdition : 1st Edition : 2007 ISBN : 8185594783, 9788185594781 Size : 170 mm x 240 mm Binding : Paperback Pages : 336 + 16 = 352` 160.00ABOUT THE BOOKThe book on “Production Technology” is prepared in two Volumes. The Vol. I contains “Manufacturing Processes and Materials”, where as Vol. II is separately published which contains “Machine Tools and Metal Removal Processes” The entire subject matter is presented in simple and lucid language. Number of figures, graphs, tables and solved examples are contributed along with the text matter to understand the subject matter easily. The book contains 12 Chapters and Appendix: * 187 Neatly drawn self-explanatory diagrams * 77 Useful Tables giving technical data * 28 Solved Examples * 159 Questions and Exercises are given at the end of chapters. It is the fervent hope of the author that this book will satisfy the needs of the Mechanical, Production, Automobile Engineering students preparing for the B.Tech/B.E. examinations of almost all the Indian Universities, Diploma examinations conducted by various Boards of Technical Education, Certificate courses as well as for the A.M.I.E., U.P.S.C., G.A.T.E. and other similar competitive and professional Examinations. It should also be of an immense help to the practising Mechanical Engineers.CONTENT1 : MANUFACTURING TECHNOLOGY 2 : MANUFACTURING MATERIALS 3 : PROPERTIES AND TESTING OF MATERIALS 4 : PLASTIC FLOW AND MECHANICAL WORKING OF METALS 5 : ROLLING AND EXTRUSION 6 : FORGING 7 : SHEET METAL FORMING 8 : SAND MOULDING PRACTICES AND METAL CASTING 9 : MELTING FURNACES 10 : WELDING AND OTHER JOINING PROCESSES 11 : PLASTICS AND PLASTIC MOULDING 12 : SURFACE FINISHING AND COATINGS Appendix : useful tables IndexPRODUCTION TECHNOLOGY VOL. I DETAILED CONTENTSChapter 1 MANUFACTURING TECHNOLOGY 1-1 Introduction 1-2 Design considerations 1-3 Factors affecting manufacturing processes 1-4 Types of materials 1-5 Manufacturing processes 1-6 Manufacturing cost 1-7 Break even point 1-8 Reasons for cost estimates 1-9 Factors affecting estimates 1-10 Skills required for cost estimates Exercise 1 Chapter 2 manufacturing materials Part I: Ferrous metals 2-1 Introduction 2-2 Types of cast iron 2-3 Iron–carbon equilibrium diagram 2-4 Types of carbon steels 2-5 Effect of residual elements on carbon steels 2-6 Alloy steels–classification 2-7 Alloying elements 2-8 Properties of stainless steels and alloy steels 2-9 Material coding (designation) system Part II: Non-ferrous metals and alloys 2-10 Aluminium and aluminium alloys 2-11 Copper and copper alloys 2-12 Magnesium and magnesium alloys 2-13 Titanium alloys 2-14 Zinc and zinc alloys 2-15 Tin and tin alloys 2-16 Bearing alloys Part III: Ceramics 2-17 Ceramics–constituents, structure and properties 2-18 Ceramic fibres 2-19 Ceramic composites Part IV: Composites 2-20 Composites 2-21 Materials for nuclear energy Exercise 2 Chapter 3 PROPERTIES AND TESTING OF MATERIALS 3-1 Properties of materials 3-2 Elastic and plastic behaviour 3-3 Stress and strain 3-4 Stress–strain diagram for carbon steel 3-5 Yield and tensile strength 3-6 Compressive, shear and torsional strengths 3-7 Ductility 3-8 Malleability 3-9 Brittleness 3-10 Hardness 3-11 Hardenability 3-12 Toughness 3-13 Stiffness 3-14 Tenacity 3-15 Resilience 3-16 Factors affecting mechanical properties 3-17 Impact strength 3-18 Hardness tests 3-19 Fracture 3-20 Factors affecting fracture 3-21 Fracture failure prevention 3-22 Fracture toughness 3-23 Factors affecting fracture toughness 3-24 Fatigue 3-25 Factors affecting fatigue properties 3-26 Fatigue test 3-27 Creep 3-28 Factors affecting creep 3-29 Mechanism of creep 3-30 Creep resisting materials 3-31 Non destructive testing (NDT) 3-32 X-rays properties and applications Exercise 3 Chapter 4 Plastic flow and mechanical working of metals 4-1 Introduction 4-2 Variables in metal working 4-3 Wrought versus cast metals 4-4 Plastic deformation 4-5 Mechanical working processes 4-6 Cold working 4-7 Warm working of metals 4-8 Hot working of metals 4-9 Work (strain) hardening 4-10 Annealing of cold worked metals 4-11 Recovery (stress relieving) 4-12 Re-crystallisation 4-13 Grain growth 4-14 Grain size measurement Questions 4 Chapter 5 Rolling and extrusion Part I: Rolling 5-1 Introduction 5-2 Principles of rolling 5-3 Methods of rolling 5-4 Classification of rolling mills 5-5 Roll passes 5-6 Break down passes 5-7 Draught 5-8 Roll Materials 5-9 Tube (roll) piercing 5-10 Defects in rolled products Part II: Extrusions 5-11 Principle of extrusion 5-12 Design considerations and limitations 5-13 Types of extrusions 5-14 Forward hot extrusion 5-15 Backward hot extrusion 5-16 Hydrostatic (forward cold) extrusion 5-17 Impact (backward cold) extrusion 5-18 Cold extrusion forging 5-19 Advantages of extrusion 5-20 Extrusion blow moulding 5-21 Extrusion pressure 5-22 Wire drawing 5-23 Tube drawing 5-24 Bar drawing 5-25 Rotary swaging 5-26 Straightening Exercise 5 Chapter 6 forging 6-1 Introduction 6-2 Drop forging impressions 6-3 Methods of forging 6-4 Forging processes 6-5 Smith forging 6-6 Drop (die) forging 6-7 Press forging 6-8 Machine (upset) forging 6-9 High energy rate forging 6-10 Roll forging 6-11 Forge welding 6-12 Forging materials 6-13 Dies for drop forging 6-14 Dies for upset forging 6-15 Forging design 6-16 Design guidelines for dies and punches 6-17 Allowances on forgings 6-18 Forging defects 6-19 General considerations 6-20 Operations before and after forging 6-21 Forged vis-à-vis cast parts Questions 6 Chapter 7 sheet metal forming 7-1 Sheet metal forming processes 7-2 Shearing operations 7-3 Shearing with dies 7-4 Angular clearance for dies 7-5 Clearances for punch and die 7-6 Minimum diameter for piercing 7-7 Design requirements for punch press parts 7-8 Shearing force and work done 7-9 Stripping force 7-10 Drawing 7-11 Deep drawing 7-12 Blank size 7-13 Punch (drawing) force 7-14 Lubrication 7-15 Punch (drawing) speed 7-16 Forming (bending) 7-17 Forming (bending) methods 7-18 Bend length 7-19 Bending load 7-20 Work done during bending 7-21 Power required 7-22 Stretch forming 7-23 Bulging 7-24 Coining, embossing and stamping 7-25 Tests on sheet metals 7-26 Spinning 7-27 Power press construction 7-28 Types of power presses 7-29 Safety devices for power press Exercise 7 Chapter 8 sand moulding practices and metal casting Part I: Sand moulding and moulding processes 8-1 Introduction 8-2 Basic steps in sand moulding 8-3 Sand mould preparation 8-4 Pattern materials and types 8-5 Pattern allowances 8-6 Moulding processes and materials 8-6-1 Processes based upon type of sand used 8-6-2 Processes based upon machine used 8-6-3 Special moulding processes 8-6-4 Methods used 8-7 Types of moulding sand 8-8 Properties of moulding sand 8-9 Sand tests 8-10 Mould and core materials 8-11 Core making 8-12 Core boxes and core plates 8-13 Core dryers 8-14 Chaplets 8-15 Core prints 8-16 Core sands and binders 8-17 Core making machines 8-18 Gating system 8-18-1 Components of gating system 8-18-2 Types of gating 8-19 Gating design 8-20 Pouring time 8-21 Fluidity of molten metal and fluidity test 8-22 Terminology Part II: Metal casting 8-23 Solidification of metals 8-24 Design for sound castings 8-25 Types of casting processes 8-26 Permanent mould castings 8-27 Expandable mould and pattern castings 8-27-1 Investment or precision castings 8-27-2 Plaster mould casting 8-27-3 Ceramic mould castings 8-27-4 Antioch casting 8-28 Permanent pattern casting 8-29 Newly developed casting process Part III: Cleaning and inspection of castings 8-30 Cleaning and finishing of castings 8-31 Casting defects and remedies 8-32 Precautions to avoid defects 8-33 Inspection of castings 8-34 Casting yield Exercise 8 Chapter 9 melting furnaces 9-1 Melting furnaces 9-2 Types of furnaces 9-3 Cupola: Melting furnace for ferrous metals 9-4 Cupola operation 9-5 Cupola charging 9-6 Cupola efficiency and heat balance 9-7 Gas and/or liquid fuel furnaces 9-8 Open hearth (reverberatory) furnace 9-9 Air furnace 9-10 Crucible furnace: For melting non-ferrous metals 9-11 Non-crucible furnaces 9-12 Rotary melting furnaces 9-13 Bessemer converter 9-14 Ladles 9-15 Electric furnaces 9-16 Temperature measurement Exercise 9 Chapter 10 welding and other joining processes 10-1 Joining processes 10-2 Welding process 10-3 Types of welding processes 10-4 Oxy-acetylene gas welding 10-5 Gas welding techniques 10-6 Arc welding 10-7 Shielded metal arc welding (SMAW) 10-8 Flux cored arc welding (FCAW) 10-9 Submerged arc welding (SAW) 10-10 Gas metal arc welding (GMAW) 10-11 Tungsten inert-gas (TIG) welding 10-12 Plasma arc welding (PAW) 10-13 Resistance welding 10-14 Solid state welding 10-15 Thermit welding 10-16 Electron beam welding (EBW) 10-17 Laser beam welding (LBW) 10-18 Electro-slag welding (ESW) 10-19 Atomic hydrogen welding (AHW) 10-20 Robotic arc welding (RAW) 10-21 Types of weld joints 10-22 Electrode classification 10-23 Soldering 10-24 Brazing 10-25 Braze welding 10-26 Metallizing 10-27 Welding of various metals 10-28 Welding defects 10-29 Thermal cutting 10-30 Mechanical fasteners 10-31 Adhesive bonding 10-32 Types of adhesives 10-33 Terminology Exercise 10 Chapter 11 PLASTICS AND PLASTIC MOULDING 11-1 Introduction 11-2 Characteristics of plastics 11-3 Thermoplastic polymers 11-4 Thermosetting polymers 11-5 Additives 11-6 Moulding processes 11-7 Compression moulding 11-8 Transfer moulding 11-9 Injection moulding 11-10 Design requirements for injection moulding 11-11 Jet blowing 11-12 Plastic extrusion process 11-13 Blow moulding 11-14 Rotational moulding 11-15 Calendering 11-16 Thermo-forming (vacuum forming) 11-17 Blown film process 11-18 Casting 11-19 Design of plastic moulds 11-20 Machining of plastics 11-21 Laminates 11-22 Foamed plastics 11-23 Summary of plastic moulding processes 11-24 Joining of plastics 11-25 Plastics in packaging Exercise 11 Chapter 12 surface finishing and coatings 12-1 Introduction 12-2 Cleaning and finishing 12-3 Chemical cleaning 12-4 Mechanical cleaning 12-5 Thermal–explosive debarring 12-6 Electro-polishing/forming 12-7 Surface coating 12-8 Properties of coatings 12-9 Types of coatings 12-10 Metallic coatings 12-11 Organic coatings 12-11-1 Constituents and application of paints 12-12 Inorganic coatings 12-13 Chemical conversions 12-14 Plastic coating 12-15 Electron beam coating Exercise 12 Appendix USEFUL TABLES Table A–1 S.I. Units, Conversion factors, Prefix names Table A–2 Conversion factors Table A–3 Prefix names, Symbols and Multiplication factors Table A–4 Applicable Indian Standards

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