Manufacturing Processes, Second Edition

1 This pageintentionally GuptaVisiting ProfessorDepartment of Mechanical , Lucknow, Technical , (London), FIE GuptaProfessor and HeadDepartment of Mechanical , Lucknow, Technical , , , MittalSenior FacultyDepartment of Mechanical , Lucknow, Technical University( Second Edition ) Copyright 2009, New Age International (P) Ltd., PublishersPublished by New Age International (P) Ltd., PublishersAll rights part of this ebook may be reproduced in any form, by photostat, microfilm, xerography,or any other means, or incorporated into any information retrieval system, electronic ormechanical, without the written permission of the publisher.

2 All inquiries should beemailed to (13) : 978-81-224-2844-5 PUBLISHING FOR ONE WORLDNEW AGE INTERNATIONAL (P) LIMITED, PUBLISHERS4835/24, Ansari Road, Daryaganj, New Delhi - 110002 Visit us at \N-MANU\ IIPreface to the Second EditionThe authors of the book Manufacturing processes are thrilled at the speed with which thefirst Edition of the book has been snapped up and exhausted within four months of its publicationnecessitating a reprint. This proves that the book has been found useful both by teachers and thestudents. This is extremely has been felt that to make the text of the book even more useful, certain changes have beenmade.

3 Therefore the text of the Unit I and Unit IV has been completely rewritten in the Second editionof the book. However, the essential features of the book have not been altered. The text is in simplenarrative style and does not presume any preliminary knowledge of the subject matter. The text isneither too detailed, nor has any essential information been left out. The text is amply make the book even more useful, the question bank has been widened and a number ofquestions of objective type have been added unitwise at the end of each is the author s belief that this Second Edition of the book will be found extremely useful byboth the faculty and the pageintentionally leftblank10D\N-MANU\ IPreface to the First EditionThe driving force behind a technological revolution has always been a certain material.

4 There would have been no industrial revolution without steel and no electronic/computer revolution without semiconductor . Similary the key behind socioeconomic development is the Manufacturing which is done by certain Manufacturing processes using certain materials. Moreovers, the primaryduty of engineers is to make life-style of people more easy and comfortable, engineers do this by making certain tools and things through certain Manufacturing processes using certain material ofdesirable present book on Manufacturing processes is what every engineer, irrespective of branchor specialization, should know.

5 Note that this book is not a book on Workshop Technology . WorkshopTechnology is usually taught as Workshop-Practice usually with 0-1-3. L-T-P, meaning by 3-labhours and 1 hour for tutorial (or lecture) for the theory of workshop tools & book on Manufacturing processes covers a wide overview of material , manufacturingprocesses and other misc. topics .Unit-I deals with Basic-Metals & alloys: Properties and Applications. Units-II and III covermajor Manufacturing processes such as Metal Forming & Casting and Machining & Welding. The lastUnit-IV covers misc. and left-over but relevant topics. The details of topics are given in the syllabusand on the content book is intended for engineers of any specialization to present an overview of manufacturingprocess and the material used in it.

6 The book would be useful as a core-course to students ofall branches and all universities throughout the book is considered to be useful universally, specially in view of syllabus of pageintentionally leftblankPreface to the Second Edition .. vPreface to the First Edition .. viiUnit IBASIC METALS AND ALLOYS : PROPERTIES AND APPLICATIONS1 PROPERTIES OF MATERIALS3 3 Properties of Materials .. 3 Stress-Strain Diagram .. 3 Malleability and 6 Stiffness and Resilience .. 6 Toughness and Impact Strength .. 7 Fracture of Material .. 8 Fatigue 9 Creep Failure .. 102 FERROUS MATERIALS11 11 Iron and Steel .. 11 Classification of Steels .. 11 Wrought Iron.

7 13 Cast Iron .. 13 Alloy 15 Heat Treatment of Carbon Steels .. 18 Contents3 NON-FERROUS METALS AND ALLOYS19 19 Properties and Uses of Non-Ferrous 19 Alloys of Copper .. 20 Cupro-Nickels .. 22 Aluminium 22 Alloys of Nickel .. 23 ObjectiveType Questions ..24-25 Unit IIINTRODUCTION TO METAL FORMING AND CASTING PROCESS1 BASIC METAL FORMING processes AND USES29 29 Advantages of Mechanical Working 29 Difference Between Hot and Cold Working .. 30 Advantages and Disadvantages of Cold and Hot Working processes .. 31 Classification of Metal Forming processes According to Type of Stress Employed .. 332 FORGING34 34 Classification of Forging .. 34 Die Forging with Power Hammers.

8 40 Open Die Forging .. 40 Impression Die Forging .. 41 Closed Die Forging .. 41 Drop Stamping or Drop Forging 41 Some Important Considerations Leading to Sound 42 Forging 42 Machine 42 Forging Defects .. 43 Heat Treatment of Forgings .. 43 Cold 443 ROLLING45 45 Nomenclature of Rolled Products .. 46 Mechanism of Rolling .. 46 Types of Rolling Mills .. 48 Rolls and Roll Pass 50 Ring 51 Cold 52 Rolling Defects .. 564 EXTRUSION, WIRE DRAWING, TUBE DRAWING AND MAKING57 65 Extrusion 58 Machines for Extrusion .. 62 Extrusion 62 Wire Drawing .. 62 Tube Drawing .. 63 Tube Making .. 655 PRESS WORK AND DIE-PUNCH ASSEMBLY66 72 Tools .. 66 Other Operations Performed with Presses.

9 68 Bending .. 68 Deep Drawing .. 69 Coining and Embossing .. 70 Guillotine 726 CASTING PROCESS73 74 Pattern 74 Types of Patterns .. 74 Moulding Sand and its Properties ..76 Mould Making Technique .. 77 Cores .. 79 Core Prints .. 79 Gates, Runners and Risers .. 81 Operation of Cupola .. 82 Casting 82 Die Casting .. 83 Steps in Die Casting .. 85 Objective Type Questions ..86 87 Unit IIIINTRODUCTION TO MACHININGAND ITS APPLICATIONS1 LATHE91 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 .. 992 SHAPERS AND PLANERS100 100 Shaping Machines or Shaper.

10 101 Cutting Tools Used in Shaping ..102 Operations Performed on Shapers .. 102 Planer or Planning Machine .. 104 Principle of Working .. 1053 DRILLING MACHINES106 110 Twist Drill .. 106 Drilling 1104 MILLING PROCESS111 111 Basic Milling Process .. 111 Types of Milling 112 Peripheral 113 Face 115 End 116 Milling 117 Horizontal Milling 1195 GRINDING PROCESS120 120 Choice of 120 Classification of Wheels .. 121 Bond and Grade .. 121 Wheel Structure .. 121 Wheel Shapes .. 122 Mounting a Wheel on Machine, Balancing, Truing and Dressing .. 123 Grinding Operations and Grinding Machines .. 1266 WELDING PROCESS127 127 Gas Welding Process.