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Manufacturing Technology, Vol. 1

Foundry, Forming and Welding
Book May 2013

CITATIONS

READS

10,295

1 author:
Nageswara Rao Posinasetti
University of Northern Iowa
185 PUBLICATIONS 316 CITATIONS
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Available from: Nageswara Rao Posinasetti

Retrieved on: 26 September 2016

Contents
Preface

ix

1. Introduction

1.1 Manufacturing Processes 1

1.2 Break-Even Analysis 4
Summary 8
Questions 8
Problems 8
Multiple-Choice Questions 9
Answers to Multiple-Choice Questions 9

2. Engineering Materials

3. Metal-Casting Processes

59

3.1 Introduction 59
3.2 Patterns 64
3.3 Moulding Materials 81
3.4 Cores 109
Summary 119
Questions 119
Problems 121
Multiple-Choice Questions 123
Answers Multiple-Choice Questions 124

4. Gating Systems for Casting

10

2.1 Engineering Properties 10

2.2 Ferrous Materials 19
2.3 Nonferrous Materials 35
2.4 Heat Treatment of Metals 39
Summary 54
Questions 55
Multiple-Choice Questions 57
Answers to Multiple-Choice Questions 58

4.1
4.2
4.3
4.4

125

Introduction 125
Gating-System Design 136
Risering Design 149
Solidification Simulation 164

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viii

Contents

Summary 167
Questions 167
Problems 168
Multiple-Choice Questions 170
Answers to Multiple-Choice Questions 171

5. Melting and Casting Quality

6. Special Casting Processes

208

6.1 Shell Moulding 208

6.2 Precision Investment Casting 211
6.3 Permanent Mould Casting 213
6.4 Die Casting 216
6.5 Vacuum Die Casting 222
6.6 Low-Pressure Die Casting 222
6.7 Centrifugal Casting 223
6.8 Continuous Casting 226
6.9 Squeeze Casting 229
6.10 Slush Casting 230
6.11 Vacuum Casting 230
Summary 231
Questions 232
Multiple-Choice Questions 232
Answers to Multiple-Choice Questions 233

7. Metal-Forming Processes

172

5.1 Melting Practices 172

5.2 Casting Cleaning 186
5.3 Casting Defects 187
5.4 Product Design for Sandcastings 190
Summary 202
Questions 202
Problems 204
Multiple-Choice Questions 206
Answers to Multiple-Choice Questions 207

234

7.1 Nature of Plastic Deformation 234

7.2 Rolling 239
7.3 Forging 253
7.4 Extrusion 279
7.5 Wire Drawing 287
7.6 Rod and Tube Drawing 290
7.7 Swaging 291
7.8 Tube Making 292
7.9 Explosive Forming 293
7.10 Thread Rolling 294
Summary 294
Questions 295

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Contents

ix

Multiple-Choice Questions 298

Answers Multiple-Choice Questions 299

8. Sheet-Metal Operations

9. Welding Processes

359

9.1 Fabrication Methods 359

9.2 Gas Welding 364
9.3 Gas Cutting 370
9.4 Electric Arc Welding 374
9.5 Arc Cutting 411
9.6 Resistance Welding 411
9.7 Welding Design 421
Summary 436
Questions 436
Problems 439
Multiple-Choice Questions 440
Answers to Multiple-Choice Questions 441

10. Other Fabrication Processes

300

8.1 Press-Tool Operations 300

8.2 Shearing Action 301
8.3 Shearing Operations 304
8.4 Drawing 310
8.5 Draw Die Design 313
8.6 Spinning 318
8.7 Bending 318
8.8 Stretch Forming 322
8.9 Embossing and Coining 323
8.10 Sheet-Metal Die Design 323
Summary 352
Questions 352
Problems 354
Multiple-Choice Questions 357
Answers to Multiple-Choice Questions 358

442

10.1 Thermit Welding 442

10.2 Electro-Slag Welding 443
10.3 Electron Beam Welding 444
10.4 Laser-Beam Welding 446
10.5 Forge Welding 447
10.6 Friction Welding 448
10.7 Diffusion Welding 449
10.8 Explosion Welding 450
10.9 Ultrasonic Metal Welding 450
10.10 Brazing 452
10.11 Braze Welding 455
10.12 Soldering 455

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Contents

Summary 457
Questions 457
Multiple-Choice Questions 458
Answers to Multiple-Choice Questions 459

11. Powder Metallurgy

12. Plastic Processing

460

11.1 Introduction 460

11.2 Production of Metallic Powder 461
11.3 Processing Methods 464
11.4 Advantages and Limitations 470
11.5 Other Compaction Methods 471
11.6 Designing For P/M 472
Summary 474
Questions 474
Multiple-Choice Questions 474
Answers to Multiple-Choice Questions 475

476

12.1 Introduction 476

12.2 Properties of Plastics 477
12.3 Additives in Plastics 478
12.4 Plastic Materials 479
12.5 Extrusion of Plastics 483
12.6 Injection Moulding 486
12.7 Blow Moulding 492
12.8 Thermoforming 496
12.9 Thermosetting Materials 499
12.10 Plastic Product Design 501
Summary 502
Questions 502
Multiple-Choice Questions 503
Answers to Multiple-Choice Questions 503

Appendix

504

Bibliograhy

508

Index

511

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