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Manufacturing Processes by H.N. Gupta.Pdf This page intentionally left blank MANUFACTURING PROCESSES (SECOND EDITION) H.N. Gupta B.Sc., G.I. Mech.E (London), FIE Visiting Professor Department of Mechanical Engineering I.E.T., Lucknow, U.P. Technical University R.C. Gupta B.Sc., B.E., M.Tech., Ph.D. Professor and Head Department of Mechanical Engineering I.E.T., Lucknow, U.P. Technical University Arun Mittal Senior Faculty Department of Mechanical Engineering I.E.T., Lucknow, U.P. Technical University Copyright © 2009, New Age International (P) Ltd., Publishers Published by New Age International (P) Ltd., Publishers All rights reserved. No 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 or mechanical, without the written permission of the publisher. All inquiries should be emailed to [email protected] ISBN (13) : 978-81-224-2844-5 PUBLISHING FOR ONE WORLD NEW AGE INTERNATIONAL (P) LIMITED, PUBLISHERS 4835/24, Ansari Road, Daryaganj, New Delhi - 110002 Visit us at www.newagepublishers.com Preface to the Second Edition The authors of the book ‘‘Manufacturing Processes’’ are thrilled at the speed with which the first edition of the book has been snapped up and exhausted within four months of its publication necessitating a reprint. This proves that the book has been found useful both by teachers and the students. This is extremely gratifying. It has been felt that to make the text of the book even more useful, certain changes have been made. Therefore the text of the Unit I and Unit IV has been completely rewritten in the second edition of the book. However, the essential features of the book have not been altered. The text is in simple narrative style and does not presume any preliminary knowledge of the subject matter. The text is neither too detailed, nor has any essential information been left out. The text is amply illustrated. To make the book even more useful, the question bank has been widened and a number of questions of objective type have been added unitwise at the end of each unit. It is the author’s belief that this second edition of the book will be found extremely useful by both the faculty and the students. AUTHORS 10D\N-MANU\TIT-MA.PM5 II This page intentionally left blank Preface to the First Edition The ‘driving force’ behind a ‘technological revolution’ has always been a certain ‘material’. 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 primary duty 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 of desirable property. The present book on ‘Manufacturing Processes’ is what every engineer, irrespective of branch or specialization, should know. Note that this book is not a book on ‘Workshop’ Technology’. ‘Workshop Technology’ is usually taught as ‘Workshop-Practice’ usually with 0-1-3. L-T-P, meaning by 3-lab hours and 1 hour for tutorial (or lecture) for the theory of workshop tools & processes. The book on ‘Manufacturing Processes’ covers a wide overview of ‘material’, manufacturing processes’ and other ‘misc. topics’. Unit-I deals with Basic-Metals & alloys: Properties and Applications. Units-II and III cover major manufacturing processes such as Metal Forming & Casting and Machining & Welding. The last Unit-IV covers misc. and left-over but relevant topics. The details of topics are given in the syllabus and on the content pages. The book is intended for engineers of any specialization to present an overview of manufacturing process and the material used in it. The book would be useful as a core-course to B.Tech. students of all branches and all universities throughout the world. The book is considered to be useful universally, specially in view of syllabus of ‘Manufacturing Processes. AUTHORS 10D\N-MANU\TIT-MA.PM5 I This page intentionally left blank Contents Preface to the Second Edition ..................................................................................................... v Preface to the First Edition ........................................................................................................ vii Unit I BASIC METALS AND ALLOYS : PROPERTIES AND APPLICATIONS 1 PROPERTIES OF MATERIALS 3–10 Introduction ................................................................................................................................... 3 Properties of Materials ................................................................................................................... 3 Stress-Strain Diagram.................................................................................................................... 3 Malleability and Ductility................................................................................................................ 6 Brittleness ...................................................................................................................................... 6 Stiffness and Resilience ................................................................................................................. 6 Toughness and Impact Strength ...................................................................................................6 Hardness ........................................................................................................................................ 7 Fracture of Material ....................................................................................................................... 8 Fatigue Failure ............................................................................................................................... 9 Creep Failure .................................................................................................................................. 9 Questions ................................................................................................................................. 10 2 FERROUS MATERIALS 11–18 Introduction ................................................................................................................................. 11 Iron and Steel............................................................................................................................... 11 Classification of Steels ................................................................................................................. 11 Wrought Iron ............................................................................................................................... 13 Cast Iron ...................................................................................................................................... 13 Alloy Steels .................................................................................................................................. 15 Heat Treatment of Carbon Steels ................................................................................................ 17 Questions ..................................................................................................................................... 18 3 NON-FERROUS METALS AND ALLOYS 19–25 Introduction ................................................................................................................................. 19 Properties and Uses of Non-Ferrous Metals ............................................................................... 19 Alloys of Copper .......................................................................................................................... 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 29–33 Introduction ................................................................................................................................. 29 Advantages of Mechanical Working Processes .......................................................................... 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 ................. 32 Questions ..................................................................................................................................... 33 2 FORGING 34–44 Introduction ................................................................................................................................
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