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