A Textbook of Production Technology (Manufacturing Processes) PDF

 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...

 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 S. CHAND & COMPANY PVT. LTD. (AN ISO 9001 : 2008 COMPANY) RAM NAGAR, NEW DELHI - 110 055  S. CHAND & COMPANY PVT. LTD. (An ISO 9001 : 2008 Company) Head Office: 7361, RAM NAGAR, NEW DELHI - 110 055 Phone: 23672080-81-82, 9899107446, 9911310888 Fax: 91-11-23677446 Shop at: schandgroup.com; e-mail: [email protected] Branches : AHMEDABAD : 1st Floor, Heritage, Near Gujarat Vidhyapeeth, Ashram Road, Ahmedabad - 380 014, Ph: 27541965, 27542369, [email protected] BENGALURU : No. 6, Ahuja Chambers, 1st Cross, Kumara Krupa Road, Bengaluru - 560 001, Ph: 22268048, 22354008, [email protected] BHOPAL : Bajaj Tower, Plot No. 2&3, Lala Lajpat Rai Colony, Raisen Road, Bhopal - 462 011, Ph: 4274723, 4209587. [email protected] CHANDIGARH : S.C.O. 2419-20, First Floor, Sector - 22-C (Near Aroma Hotel), Chandigarh -160 022, Ph: 2725443, 2725446, [email protected] CHENNAI : No.1, Whites Road, Opposite Express Avenue, Royapettah, Chennai - 600014 Ph. 28410027, 28410058, [email protected] COIMBATORE : 1790, Trichy Road, LGB Colony, Ramanathapuram, Coimbatore -6410045, Ph: 2323620, 4217136 [email protected] (Marketing Office) CUTTACK : 1st Floor, Bhartia Tower, Badambadi, Cuttack - 753 009, Ph: 2332580; 2332581, [email protected] DEHRADUN : 1st Floor, 20, New Road, Near Dwarka Store, Dehradun - 248 001, Ph: 2711101, 2710861, [email protected] GUWAHATI : Dilip Commercial (Ist floor), M.N. Road, Pan Bazar, Guwahati - 781 001, Ph: 2738811, 2735640 [email protected] HYDERABAD : Padma Plaza, H.No. 3-4-630, Opp. Ratna College, Narayanaguda, Hyderabad - 500 029, Ph: 27550194, 27550195, [email protected] JAIPUR : 1st Floor, Nand Plaza, Hawa Sadak, Ajmer Road, Jaipur - 302 006, Ph: 2219175, 2219176, [email protected] JALANDHAR : Mai Hiran Gate, Jalandhar - 144 008, Ph: 2401630, 5000630, [email protected] KOCHI : Kachapilly Square, Mullassery Canal Road, Ernakulam, Kochi - 682 011, Ph: 2378740, 2378207-08, [email protected] KOLKATA : 285/J, Bipin Bihari Ganguli Street, Kolkata - 700 012, Ph: 22367459, 22373914, [email protected] LUCKNOW : Mahabeer Market, 25 Gwynne Road, Aminabad, Lucknow - 226 018, Ph: 4076971, 4026791, 4065646, 4027188, [email protected] MUMBAI : Blackie House, IInd Floor, 103/5, Walchand Hirachand Marg, Opp. G.P.O., Mumbai - 400 001, Ph: 22690881, 22610885, [email protected] NAGPUR : Karnal Bagh, Near Model Mill Chowk, Nagpur - 440 032, Ph: 2720523, 2777666 [email protected] PATNA : 104, Citicentre Ashok, Mahima Palace , Govind Mitra Road, Patna - 800 004, Ph: 2300489, 2302100, [email protected] PUNE : Sadguru Enclave, Ground floor, Survey No. 114/3, Plot no. 8 Alandi Road , Vishrantwadi Pune – 411015 Ph: 64017298 [email protected] RAIPUR : Kailash Residency, Plot No. 4B, Bottle House Road, Shankar Nagar, Raipur - 492 007, Ph: 2443142,Mb. : 09981200834, [email protected] (Marketing Office) RANCHI : Shanti Deep Tower, Opp.Hotel Maharaja, Radium Road, Ranchi-834001 Mob. 09430246440 [email protected] SILIGURI : 122, Raja Ram Mohan Roy Road, East Vivekanandapally, P.O., Siliguri, Siliguri-734001, Dist., Jalpaiguri, (W.B.) Ph. 0353-2520750 (Marketing Office) [email protected] VISAKHAPATNAM: No. 49-54-15/53/8, Plot No. 7, 1st Floor, Opp. Radhakrishna Towers, Seethammadhara North Extn., Visakhapatnam - 530 013, Ph-2782609 (M) 09440100555, [email protected] (Marketing Office) © 1996, Dr. P.C. Sharma All rights reserved. No part of this publication may be reproduced or copied in any material form (including photocopying or storing it in any medium in form of graphics, electronic or mechanical means and whether or not transient or incidental to some other use of this publication) without written permission of the copyright owner. Any breach of this will entail legal action and prosecution without further notice. Jurisdiction : All disputes with respect to this publication shall be subject to the jurisdiction of the Courts, Tribunals and Forums of New Delhi, India only. First Edition 1996 Subsequent Editions & Reprints 1999, 2001, 2004, 2005, 2007, 2008, 2009, 2010, 2011, 2012 Eighth Revised Edition 2014 ISBN : 81-219-1114-1 Code : 10C 160 PRINTED IN INDIA By Rajendra Ravindra Printers Pvt. Ltd., 7361, Ram Nagar, New Delhi -110 055 and published by S. Chand & Company Pvt. Ltd., 7361, Ram Nagar, New Delhi -110 055.  PREFACE TO THE EIGHTH EDITION The printing of the eighth edition of the book has provided me with an opportunity to completely go through the text. Minor additions and improvements have been carried out wherever needed. All the figures have been redone on computer to make clear and sharp. I am really thankful to the management and the editorial team of S.Chand & Company Pvt. Ltd., New Delhi for doing an excellent job in publishing the latest edition of the book. Pointing out of errors and misprints in the text will be highly obliged and thankfully acknowledged. Any suggestions for further improvement of the book will be highly appreciated. Dr. P.C. SHARMA Disclaimer : While the author of this book has made every effort to avoid any mistakes or omissions and has used his skill, expertise and knowledge to the best of his capacity to provide accurate and updated information the author and S. Chand do not give any representation or warranty with respect to the accuracy or completeness of the contents of this publication and are selling this publication on the condition and understanding that they shall not be made liable in any manner whatsoever. S.Chand and the author expressly disclaim all and any liability/responsibility to any person, whether a purchaser or reader of this publication or not, in respect of anything and everything forming part of the contents of this publication. S. Chand shall not be responsible for any errors, omissions or damages arising out of the use of the information contained in this publication. Further, the appearance of the personal name, location, place and incidence, if any; in the illustrations used herein is purely coincidental and work of imagination. Thus the same should in no manner be termed as defamatory to any individual.  PREFACE TO THE FIRST EDITION The book ‘‘A Textbook of Production Engineering’’ by the author has been very popular with the readers, for the last fourteen years. The readers have been writing to the author to bring out a book exclusively dealing with manufacturing processes. The author feels very happy to bring out this book A Textbook of Production Technology to meet the long standing demand of the readers. It has been author’s intention to provide a broad-based introduction to a wide variety of manufacturng processes. The text is designed to be used by engineering (Mechanical, Production, Industrial and Aeronautical) students. The book will also be useful to students appearing in various professional and competitive examinations (AMIE, Engineering Services, Administrative Services, GATE, etc). The author hopes that practicing engineers too will find the book useful. My sincere thanks are due to the publisher S. Chand & Company Ltd. for the excellent work done in publishing this book at a reasonable price, and for bringing out the book in a record time and such a nice format. I am also grateful to Managing Director, Shri Rajendra Kumar Gupta and Director, Shri Ravindra Kumar Gupta for showing personal interest. Finally, I sincerely hope that the book will meet the needs of the readers. All the suggestions to improve the text of the book will always be welcomed. P.C. SHARMA  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 (ix)