Manufacturing Science/ Production Technology (Engg. Materials, Manufacturing Process, Overview of Automation) Contents Preface to the Second Edition ................ Preface to the First Edition ..................................... Unit I BASIC METALS AND ALLOYS : PROPERTIES AND APPLICATIONS 1 PROPERTIES OF MATERIALS Introduction…………………………………………………………..3 Properties of Materials………………………………………………..3 Stress-StrainDiagram…………………………………………………3 Malleability and Ductility ……………………………………………6 Brittleness………………………………………………………………………………………………………6 Stiffness and Resilienc……………………………………………………………………………………6 Toughness and Impact Strength………………………………………………………………………6 Hardness……………………………………………………………………………………………………………7 Fracture of Materia………………………………………………………………………………………………8 Fatigue Failure……………………………………………………………………………………………………..9 Creep Failure…………………………………………………………………………………………………………9 Questions………………………………………………………………………………………………………………10 2 FERROUS MATERIALS Introduction Iron and Steel Classification of Steel Wrought Iron Cast Iron Alloy Steels Heat Treatment of Carbon Steel Questions 3 NON-FERROUS METALS AND ALLOYS Introduction………………..19 Properties and uses of non-ferrous metals ………………………….19 Alloys of Coppe………………………………………………………….20 Cupro-Nickels………………………………………………..22 Aluminium Alloys…………………………………………22 Alloys of Nickel………………………………………………….22 Questions………………………………………………………………23 Objective Type Questions……………………………24-25 Unit II INTRODUCTION TO METAL FORMING AND CASTING PROCESS 1 BASIC METAL FORMING PROCESSES AND USES Introduction……………………………………..29 Advantages of Mechanical Working Processes……………..29 Difference Between Hot and Cold Working………………………………………30 Advantages and Disadvantages of Cold and Hot Working Processe……31 Classification of Metal Forming Processes According to Type of Stress Employed….32 Questions…………………………………………33 2 FORGING Introduction……………………………………………34 Classification of Forging………………….34 Die Forging with Power Hammers………………………………….40 Open Die Forging…………………………………………..40 Impression Die Forging……………………………………41 Closed Die Forging……………………………….41 Drop Stamping or Drop Forging Hammers………………………..41 Some Important Considerations Leading to Sound Forgings…………………..42 Forging Presses………………………………………42 Machine Forging……………………………..42 Forging Defects…………………………………..43 Heat Treatment of Forgings…………………….43 Cold Forging…………………………………………..44 Questions……………………………44 3 ROLLING Introduction……………………………………45 Nomenclature of Rolled Products………………………46 Mechanism of Rollin……………………………46 Types of Rolling Mills……………………………………….48 Rolls and Roll Pass Design…………………………………50 Ring Rolling……………………………………………51 Cold Rolling……………………………………….52 Rolling Defect…………………………………..53 Questions…………………………56 4 EXTRUSIONS, WIRE DRAWING, TUBE DRAWING AND MAKING 57-65 Extrusion Processes………………………………….58 Machines for Extrusion………………………………………………………..62 Extrusion Defects………………………………………….62 Wire Drawing…………………………………………………….62 Tube Drawing……………………………………………….63 Tube Making……………………………………..64 Questions…………………………………65 5 PRESS WORK AND DIE-PUNCH ASSEMBLY Tools…………………………….66 Other Operations Performed with Press……………………………68 Bending…………………………………68 Deep Drawing………………………………………68 Coining and Embossing……………………….69 Coining…………………………..70 Guillotine Shear…………………………71 Questions………………………..72 . 6 CASTING PROCESS Introduction…………………………..73 Patterns…………………………………………..74 Types of Patterns……………………………74 Moulding Sand and its Propertie…………………………………………..76 Mould Making Technique………………………77 Cores…………………………..79 Core Print………………………………………………………79 Gates, Runners and Risers………………………………………..80 Cupola…………………………81 Construction………………………………..81 Operation of Cupola………………………….82 Casting Defects………………………..82 Die Casting………………………83 Steps in Die Casting…………………………………………………………………….84 Questions……………………………………..85 Objective Type Question………………………………..86-87 Unit III INTRODUCTION TO MACHINING AND ITS APPLICATIONS 1 LATHE Introduction………………………….91 Centre Lathe………………………………………92 Cutting Tools Used on the Lathe……………………..94 Holding the Work Piece in the Chuck and Centering………………….95 Taper Turning……………………….96 Profile or Form Turning……………………….98 Questions………………….99 2 SHAPERS AND PLANERS Introduction…………………………….100 Shaping Machines or Shaper………………………………..100 Drive………………………101 Cutting Tools Used in Shaping……………………..102 Operations Performed on Shapers…………………………..102 Planer or Planning Machine…………………………..104 Principle of Working…………………….104 Questions…………………..105 3 DRILLING MACHINES Twist Drill…………………106 Drilling Machines…………………..107 Questions…………………110 4 MILLING PROCESS Introduction……………………111 Basic Milling Proces…………………………111 Types of Milling Processes………………………………112 Peripheral Milling…………………………113 Face Milling……………………..115 End Milling………………………………..116 Milling Machines…………………………117 Horizontal Milling Machine………………………………………………..117 Questions…………………….119 5 GRINDING PROCESS Introduction………………………………………….120 Choice of Abrasives…………………………….120 Classification of Wheels………………….121 Grit…………………… 121 Bond and Grade………………121 Wheel Structure……………………..121 Wheel Shape…………………..122 Mounting a Wheel on Machine, Balancing, Truing and Dressing….123 Grinding Operations and Grinding Machines………………123 Coolant………………126 Questions…………….126 6 WELDING PROCESS Classification…………………………….127 Gas Welding Process……………………127 Equipment Needed for Gas Welding…………………………..128 Types of Flames…………………..130 Welding Operation…………………………130 Use of Filler Rods and Fluxes ………………………133 Oxyacetylene Cutting……..133 Arc Welding……………..133 Striking an Arc………………………134 Heat Affected Zone…………………….135 Arc Blow…………………135 Welding Positions………………………………….135 Arc Welding Defect……………………….136 Electric Resistance Welding……………………………….136 Soldering and Brazing……………………………………………………..140 Soldering Process…………………………140 Brazing Process…………………………………………………………………………………..140 Questions………………………………….141 Objective Type Question……………………142-143 Unit IV MISCELLANEOUS TOPICS 1 IMPORTANCE OF MATERIALS AND MANUFACTURING Introduction………………………………..147 Proper Selection of Material………………..147 Importance of Materials……………………148 Historical Perspective……………………………………………………………149 Materials as Driving-Force Behind Technological Development…….149 Direct and Indirect Linkages Among Materials, Manufacturing, Technological Development and Socioeconomic Improvement……152 Conclusion…………………….152 Questions………………………………………..153 2 LOCATION AND LAYOUT OF PLANTS, PRODUCTION AND Productivity Introduction…………………………154 Location of Plants…………………..154 Layout of Plants……………………………………..154 Advantages of a Good Layout……………………………….155 Types of Layout…………………….155 Types of Production……………………………..156 Production and Productivity………………………….157 Questions……………………157 3 NON-METALLIC MATERIALS Common Types and Uses of Wood…………………….158 Uses of Wood………………….159 Cement Concrete……………………………………..159 Ceramics…………………….160 Rubbers……………………………………..160 Plastics…………………………………………………………..162 Composite Materials…………………………165 Questions…………………………167 4 MISCELLANEOUS PROCESSES Powder Metallurgy Process……………………168 Plastic Products Manufacturing Processes……………………169 Galvanising Process……………………..171 Electroplating Process……………………..172 Faraday’s Laws of Electrolysis…………………………….173 Questions………………173 Objective Type Questions……………………………174-175 QUESTION PAPER……………………..177-179 .
Manufacturing Science/ Production Technology (Engg. Materials, Manufacturing Process, Overview of Automation)
Contents
Preface to the Second Edition ................
Preface to the First Edition .....................................
Unit I
BASIC METALS AND ALLOYS : PROPERTIES AND APPLICATIONS
1 PROPERTIES OF MATERIALS
Introduction…………………………………………………………..3
Properties of Materials………………………………………………..3
Stress-StrainDiagram…………………………………………………3
Malleability and Ductility ……………………………………………6
Brittleness………………………………………………………………………………………………………6
Stiffness and Resilienc……………………………………………………………………………………6
Toughness and Impact Strength………………………………………………………………………6
Hardness……………………………………………………………………………………………………………7
Fracture of Materia………………………………………………………………………………………………8
Fatigue Failure……………………………………………………………………………………………………..9
Creep Failure…………………………………………………………………………………………………………9
Questions………………………………………………………………………………………………………………10
2 FERROUS MATERIALS
Introduction
Iron and Steel
Classification of Steel
Wrought Iron
Cast Iron
Alloy Steels
Heat Treatment of Carbon Steel
Questions
3 NON-FERROUS METALS AND ALLOYS
Introduction………………..19
Properties and uses of non-ferrous metals ………………………….19
Alloys of Coppe………………………………………………………….20
Cupro-Nickels………………………………………………..22
Aluminium Alloys…………………………………………22
Alloys of Nickel………………………………………………….22
Questions………………………………………………………………23
Objective Type Questions……………………………24-25
Unit II
INTRODUCTION TO METAL FORMING AND CASTING PROCESS
1 BASIC METAL FORMING PROCESSES AND USES
Introduction……………………………………..29
Advantages of Mechanical Working Processes……………..29
Difference Between Hot and Cold Working………………………………………30
Advantages and Disadvantages of Cold and Hot Working Processe……31
Classification of Metal Forming Processes According to Type of Stress Employed….32
Questions…………………………………………33
2 FORGING
Introduction……………………………………………34
Classification of Forging………………….34
Die Forging with Power Hammers………………………………….40
Open Die Forging…………………………………………..40
Impression Die Forging……………………………………41
Closed Die Forging……………………………….41
Drop Stamping or Drop Forging Hammers………………………..41
Some Important Considerations Leading to Sound Forgings…………………..42
Forging Presses………………………………………42
Machine Forging……………………………..42
Forging Defects…………………………………..43
Heat Treatment of Forgings…………………….43
Cold Forging…………………………………………..44
Questions……………………………44
3 ROLLING
Introduction……………………………………45
Nomenclature of Rolled Products………………………46
Mechanism of Rollin……………………………46
Types of Rolling Mills……………………………………….48
Rolls and Roll Pass Design…………………………………50
Ring Rolling……………………………………………51
Cold Rolling……………………………………….52
Rolling Defect…………………………………..53
Questions…………………………56
4 EXTRUSIONS, WIRE DRAWING, TUBE DRAWING AND MAKING 57-65
Extrusion Processes………………………………….58
Machines for Extrusion………………………………………………………..62
Extrusion Defects………………………………………….62
Wire Drawing…………………………………………………….62
Tube Drawing……………………………………………….63
Tube Making……………………………………..64
Questions…………………………………65
5 PRESS WORK AND DIE-PUNCH ASSEMBLY
Tools…………………………….66
Other Operations Performed with Press……………………………68
Bending…………………………………68
Deep Drawing………………………………………68
Coining and Embossing……………………….69
Coining…………………………..70
Guillotine Shear…………………………71
Questions………………………..72
.
6 CASTING PROCESS
Introduction…………………………..73
Patterns…………………………………………..74
Types of Patterns……………………………74
Moulding Sand and its Propertie…………………………………………..76
Mould Making Technique………………………77
Cores…………………………..79
Core Print………………………………………………………79
Gates, Runners and Risers………………………………………..80
Cupola…………………………81
Construction………………………………..81
Operation of Cupola………………………….82
Casting Defects………………………..82
Die Casting………………………83
Steps in Die Casting…………………………………………………………………….84
Questions……………………………………..85
Objective Type Question………………………………..86-87
Unit III
INTRODUCTION TO MACHINING
AND ITS APPLICATIONS
1 LATHE
Introduction………………………….91
Centre Lathe………………………………………92
Cutting Tools Used on the Lathe……………………..94
Holding the Work Piece in the Chuck and Centering………………….95
Taper Turning……………………….96
Profile or Form Turning……………………….98
Questions………………….99
2 SHAPERS AND PLANERS
Introduction…………………………….100
Shaping Machines or Shaper………………………………..100
Drive………………………101
Cutting Tools Used in Shaping……………………..102
Operations Performed on Shapers…………………………..102
Planer or Planning Machine…………………………..104
Principle of Working…………………….104
Questions…………………..105
3 DRILLING MACHINES
Twist Drill…………………106
Drilling Machines…………………..107
Questions…………………110
4 MILLING PROCESS
Introduction……………………111
Basic Milling Proces…………………………111
Types of Milling Processes………………………………112
Peripheral Milling…………………………113
Face Milling……………………..115
End Milling………………………………..116
Milling Machines…………………………117
Horizontal Milling Machine………………………………………………..117
Questions…………………….119
5 GRINDING PROCESS
Introduction………………………………………….120
Choice of Abrasives…………………………….120
Classification of Wheels………………….121
Grit…………………… 121
Bond and Grade………………121
Wheel Structure……………………..121
Wheel Shape…………………..122
Mounting a Wheel on Machine, Balancing, Truing and Dressing….123
Grinding Operations and Grinding Machines………………123
Coolant………………126
Questions…………….126
6 WELDING PROCESS
Classification…………………………….127
Gas Welding Process……………………127
Equipment Needed for Gas Welding…………………………..128
Types of Flames…………………..130
Welding Operation…………………………130
Use of Filler Rods and Fluxes ………………………133
Oxyacetylene Cutting……..133
Arc Welding……………..133
Striking an Arc………………………134
Heat Affected Zone…………………….135
Arc Blow…………………135
Welding Positions………………………………….135
Arc Welding Defect……………………….136
Electric Resistance Welding……………………………….136
Soldering and Brazing……………………………………………………..140
Soldering Process…………………………140
Brazing Process…………………………………………………………………………………..140
Questions………………………………….141
Objective Type Question……………………142-143
Unit IV
MISCELLANEOUS TOPICS
1 IMPORTANCE OF MATERIALS AND MANUFACTURING
Introduction………………………………..147
Proper Selection of Material………………..147
Importance of Materials……………………148
Historical Perspective……………………………………………………………149
Materials as Driving-Force Behind Technological Development…….149
Direct and Indirect Linkages Among Materials, Manufacturing,
Technological Development and Socioeconomic Improvement……152
Conclusion…………………….152
Questions………………………………………..153
2 LOCATION AND LAYOUT OF PLANTS, PRODUCTION
AND Productivity
Introduction…………………………154
Location of Plants…………………..154
Layout of Plants……………………………………..154
Advantages of a Good Layout……………………………….155
Types of Layout…………………….155
Types of Production……………………………..156
Production and Productivity………………………….157
Questions……………………157
3 NON-METALLIC MATERIALS
Common Types and Uses of Wood…………………….158
Uses of Wood………………….159
Cement Concrete……………………………………..159
Ceramics…………………….160
Rubbers……………………………………..160
Plastics…………………………………………………………..162
Composite Materials…………………………165
Questions…………………………167
4 MISCELLANEOUS PROCESSES
Powder Metallurgy Process……………………168
Plastic Products Manufacturing Processes……………………169
Galvanising Process……………………..171
Electroplating Process……………………..172
Faraday’s Laws of Electrolysis…………………………….173
Questions………………173
Objective Type Questions……………………………174-175
QUESTION PAPER……………………..177-179
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