Automotive Manufacturing Processes: A Case Study Approach

Cover
Half Title
Title Page
Copyright Page
Dedication
Table of Contents
Preface
	Salient Features of the Book
Acknowledgements
About the Authors
Abbreviations
1 Automotive Materials
	Learning Objectives
	1.1 Introduction
	1.2 Requirements of Ideal Automotive Materials
	1.3 Classification of Materials Used in Automobiles
		1.3.1 Metals and Alloys
		1.3.2 Ceramics
		1.3.3 Glasses and Glass-Ceramic
		1.3.4 Polymers (Plastics)
		1.3.5 Semiconductors
		1.3.6 Composite Materials
		1.3.7 Others
	1.4 Properties of Automotive Materials
	1.5 Ferrous Materials and Their Alloys: Cast Iron and Steels—Types, Properties, and Applications
		1.5.1 Cast Iron Classifications
			1.5.1.1 Gray Cast Iron
			1.5.1.2 White Cast Iron
			1.5.1.3 Malleable Cast Iron
			1.5.1.4 Nodular Cast Iron
			1.5.1.5 Mottled Cast Iron
			1.5.1.6 Chilled Cast Iron
		1.5.2 Plain Carbon Steel
			1.5.2.1 Low-Carbon Steels
			1.5.2.2 Medium-Carbon Steels
			1.5.2.3 High-Carbon Steels
		1.5.3 Alloy Steels
			1.5.3.1 Stainless Steels
			1.5.3.2 Austenitic Stainless Steels
			1.5.3.3 Ferritic Stainless Steels
			1.5.3.4 Martensitic Stainless Steels
			1.5.3.5 Tool Steels
	1.6 Material Selection Process in the Automotive Industry
	1.7 Summary
	1.8 Review Questions
2 Nonferrous Materials
	Learning Objectives
	2.1 Introduction
	2.2 Nonferrous Materials and Their Alloys
		2.2.1 Copper and Its Alloys
			2.2.1.1 Properties and Uses
		2.2.2 Copper Alloys
		2.2.3 Aluminium and Its Alloys
		2.2.4 Magnesium and Its Alloys
		2.2.5 Titanium Alloy
	2.3 Ceramics – Properties of Ceramic Materials and Applications
	2.4 Polymer Materials
		2.4.1 Thermo-Setting Plastics, Rubber
		2.4.2 Thermoplastics
		2.4.3 Thermosetting Polymers
		2.4.4 Applications of Polymers
	2.5 Glass Fibre and Carbon Fibre: Properties and Applications
		2.5.1 Glass Fibre
		2.5.2 Carbon Fibre
	2.6 Modern Materials Used in the Automotive Industry
	2.7 Material Decision-Making Process
	2.8 Business Factors Affecting Material Selection
	2.9 Summary
	2.10 Review Questions
3 Heat Treatment
	Learning Objectives
	3.1 Introduction: Concept of Phase and Phase Transformation
		3.1.1 Concept of Phase
		3.1.2 Phase Transformation
	3.2 Iron–Iron Carbide Phase Equilibrium Diagram
	3.3 Common Heat Treatment Processes and Their Applications
		3.3.1 Types of Heat Treatment Processes
		3.3.2 Annealing
		3.3.3 Normalising
		3.3.4 Hardening and Quenching
		3.3.5 Tempering
	3.4 Surface Hardening Processes: Gas Carburising, Nitriding, Cyaniding
		3.4.1 Carburising
		3.4.2 Cyaniding
		3.4.3 Nitriding
		3.4.4 Carbonitriding
	3.5 Induction and Flame Hardening
		3.5.1 Induction Hardening
		3.5.2 Flame Hardening
	3.6 Heat Treatment Processes in the Automotive Industry
	3.7 Summary
	3.8 Review Questions
4 Moulding and Casting
	Learning Objectives
	4.1 Introduction
	4.2 Pattern Making
		4.2.1 Types of Pattern
		4.2.2 Pattern Materials
	4.3 Moulding
		4.3.1 Classification of Moulding
		4.3.2 Green Sand Moulding
		4.3.3 Core
	4.4 Casting
		4.4.1 Permanent Mould Casting
		4.4.2 Centrifugal Casting
		4.4.3 Pressure Die Casting
	4.5 Pouring (Gating Design)
		4.5.1 Aspiration Effect
		4.5.2 Effects of Friction and Velocity Distribution
	4.6 Solved Examples
	4.7 Defects in Casting: Causes and Remedies
	4.8 Automotive Moulding
	4.9 Metal Casting Applications in the Automotive Industry
	4.10 Summary
	4.11 Unsolved Examples
	4.12 Review Questions
5 Forging Process
	Learning Objectives
	5.1 Introduction
	5.2 Forging and Forgeability
		5.2.1 Forging
		5.2.2 Forgeability
	5.3 Advantages and Disadvantages
	5.4 Forging Tools and Forging Methods: Hand Tools and Forging Operations
	5.5 Power Forging: Spring Hammers, Drop Hammers
	5.6 Defects in Forged Parts and Their Causes
	5.7 Forged Automotive Components
	5.8 Metallurgical Spectrum of Forging
	5.9 Summary
	5.10 Review Questions
6 Welding Process
	Learning Objectives
	6.1 Introduction
	6.2 Concept of Welding and Weldability
	6.3 Arc Welding: Arc Welding Equipment, Electrodes
	6.4 Gas Welding: Types of Flames, Gas Welding Equipment
	6.5 Resistance Welding: Types and Applications
	6.6 Design of Weld Joints, Butt Joints, Fillet Joints
	6.7 Strength of Transverse Fillet Welds
	6.8 Solved Examples
	6.9 Allied Processes: Soldering, Brazing
	6.10 Special Welding Processes: Plasma Arc Welding, Metal Inert Gas Arc Welding (MIG), TIG Welding
	6.11 Automotive Applications of Welding
	6.12 Welding Procedure for Automotive Manufacturing
	6.13 Summary
	6.14 Unsolved Examples
	6.15 Review Questions
7 Material Removal Processes
	Learning Objectives
	7.1 Introduction
	7.2 Mechanics of Metal Cutting
		7.2.1 Mechanism of Chip Formation
		7.2.2 Discontinuous Chips Or Segmental Chips
		7.2.3 Continuous Chips With Built Up Edge
		7.2.4 Serrated Chips
		7.2.5 Types of Metal Cutting Processes
	7.3 Cutting Tools
		7.3.1 Cutting Tool Geometry
		7.3.2 Tool Signature
	7.4 Cutting Tools Materials
	7.5 Advanced Cutting Tool Materials
		7.5.1 Coated Carbides
		7.5.2 Cermets
		7.5.3 Coronite
		7.5.4 High-Performance Ceramics (HPC)
		7.5.5 Plain Nitride Ceramics Tools
		7.5.6 SIALON Tools
		7.5.7 Nitrite Toughened
		7.5.8 Zirconia Toughened Alumina (ZTA)
		7.5.9 Cubic Boron Nitride (CBN)
		7.5.10 Diamond
		7.5.11 Polycrystalline Diamond (PCD)
		7.5.12 Diamond-Coated Carbide Tools
		7.5.13 Carbon With Diamond-Like Properties (DLC)
		7.5.14 Carbonado
		7.5.15 Extra-Large Synthetic Diamond
	7.6 Tool Coating Process
	7.7 Tool Failure
	7.8 Cutting Forces and Power Consumption
		7.8.1 Chip Thickness Ratio (Or Cutting Ratio)
		7.8.2 Velocity Relationship in Orthogonal Cutting
		7.8.3 Forces Acting On the Chip in Orthogonal Cutting (Merchant’s Analysis)
		7.8.4 Stress and Strain On the Chip
		7.8.5 Forces of a Single-Point Tool
		7.8.6 Popular Theories On the Mechanics of Metal Cutting
		7.8.7 Tool Life
		7.8.9 Factors Affecting Tool Life
	7.9 Coolant Technology
		7.9.1 Types of Cutting Fluids
	7.10 Reconditioning of the Tools
	7.11 Special Case Study: Development of a Hybrid Tool for Boring, Reaming and Chamfering Operation
		7.11.1 Introduction
		7.11.2 Development of the Tool
		7.11.3 Conclusion
	7.12 Solved Examples On Tool Life, Machining Forces
	7.13 Summary
	7.14 Unsolved Examples
	7.15 Review Questions
8 Plastic Processing in the Automotive Industry
	Learning Objectives
	8.1 Introduction
	8.2 Extrusion of Plastics
		8.2.1 Types of Extrusion Process
	8.3 Injection Moulding – Plunger and Screw Machines
		8.3.1 Screw Type Injection Moulding Machine
		8.3.2 Plunger Type Injection Moulding
	8.4 Compression Moulding
	8.5 Transfer Moulding – Typical Industrial Applications
	8.6 Blow Moulding
	8.7 Advanced Plastics Used in the Automobile Sector
	8.8 Usage and Advantages of Plastic Components in the Automotive Industry
	8.9 Summary
	8.10 Review Questions
9 Powder Metallurgy
	Learning Objectives
	9.1 Introduction
	9.2 Production of Metallic Powder
	9.3 Processing Methods
	9.4 Advantages and Disadvantages
	9.5 Secondary Operations
	9.6 Automotive Applications of Powder Metallurgy
	9.7 Summary
	9.8 Review Questions
10 Surface Treatment
	Learning Objectives
	10.1 Introduction
	10.2 Selection and Use of Surface Treatment and Cleaning Processes
	10.3 Surface Cleaning Processes: Sand Blasting, Tumbling, Alkaline, Acid and Electrolytic Cleaning
	10.4 Surface Coating Processes: Electroplating, Galvanising, Metal Spraying, Painting
	10.5 Automotive Painting Process, Ingredients, Painting Procedure
	10.6 Surface Finishing Process: Polishing, Buffing, Burnishing, Super Finishing
	10.7 Surface Treatments for Automotive Manufacturing
	10.8 Applications of Surface Treatments in the Car Industry
	10.9 Summary
	10.10 Review Questions
11 Press Shop Process
	Learning Objectives
	11.1 Introduction
	11.2 Sheet Metal Working: Bending, Forming and Deep Drawing
		11.2.1 Bending
		11.2.2 Forming
		11.2.3 Deep Drawing
	11.3 Difference Between Punching, Piercing and Blanking
		11.3.1 Punching
		11.3.2 Piercing
		11.3.3 Blanking
	11.4 Mechanics of the Forming Process
	11.5 Determination of the Drawing Force and Power
	11.6 Determination of Maximum Allowable Reduction
	11.7 Determination of Work Load
	11.8 Solved Examples
	11.9 Press – Types, Construction and Working
		11.9.1 Types of Presses
		11.9.2 Construction
	11.10 Press Tools – Dies, Punches
		11.10.1 Dies
		11.10.2 Punches
	11.11 Automotive Stamping Manufacturing Process
	11.12 Identification of Major Auto Components By Material and Process
	11.13 Summary
	11.14 Review Questions
12 Case Studies of Automotive Manufacturing Units
	Learning Objectives
	12.1 Case Study 1: Heat Treatment of Automotive Components – Current Status and Future Trends
		12.1.1 Introduction
		12.1.2 Materials and Their Applications in Automobiles
			12.1.2.1 Bake Hardening Steel Sheets
			12.1.2.2 High-Tensile-Strength Steel Sheets
			12.1.2.3 Corrosion-Resistant Coated Steel Sheets
			12.1.2.4 Constructional Steels
			12.1.2.5 Case Hardening Steels
			12.1.2.6 Heat-Resistant Steels
			12.1.2.7 Copper Alloys
			12.1.2.8 Aluminium Alloys
			12.1.2.9 Magnesium Alloys
			12.1.2.10 Titanium Alloys
			12.1.2.11 Composite Materials
			12.1.2.12 Plastics and Rubber
			12.1.2.13 Glass and Ceramics
		12.1.3 Heat Treatment
			12.1.3.1 Types of Heat Treatment
			12.1.3.2 Processing Technology in Heat Treatment
			12.1.3.3 Carburising and Carbonitriding
			12.1.3.4 Nitrocarburising
			12.1.3.5 Induction Hardening
			12.1.3.6 Powder Metallurgy and Sintering
		12.1.4 Key Issue in Heat Treatment: Atmosphere Control
			12.1.4.1 Carbon Potential Control
				12.1.4.1.1 Gas Carburising Processes
				12.1.4.1.2 Reduced Pressure Carburising (Vacuum Carburising)
				12.1.4.1.3 High-Pressure Gas Quenching
				12.1.4.1.4 Carbonitriding
				12.1.4.1.5 Low-Temperature Nitrocarburising and Oxy-Nitrocarburising
		12.1.5 Surface Modification and Treatment
			12.1.5.1 Coatings of Solid Lubricant
		12.1.6 Emerging Technologies in Materials, Heat Treatment and Surface Processing Operations
			12.1.6.1 Materials
			12.1.6.2 Carburising and Carbonitriding
		12.1.7 Conclusion
	12.2 Case Study 2: Casting in the Automotive Industry
		12.2.1 Introduction
		12.2.2 Automotive Manufacturing and Die Casting
		12.2.3 HID Light Ballast Unit Housing
		12.2.4 Transmission Range Control Module (TRCM) Housing
		12.2.5 Ford Hydra ECU Housing
		12.2.6 Conclusion
	12.3 Case Study 3: Performance of Forging
		12.3.1 Introduction
		12.3.2 Conclusion
	12.4 Case Study 4: Automotive Applications of Welding Technology
		12.4.1 Introduction
		12.4.2 Automotive Applications of Welding
			12.4.2.1 Resistance Spot Welding
			12.4.2.2 Resistance Seam Welding
			12.4.2.3 Friction Welding
			12.4.2.4 Medium-Frequency Welding
			12.4.2.5 Magnetic Pulse Welding
		12.4.3 Conclusion
	12.5 Case Study 5: Machining Operation in the Automotive Industry
		12.5.1 Introduction
		12.5.2 Study Framework
		12.5.3 SMED Implementation Program
			12.5.3.1 Separate Internal and External Setups
			12.5.3.2 Stage 3 (Streamline Operations)
		12.5.4 Conclusion
	12.6 Case Study 6: Automotive Plastic Processing
		12.6.1 Introduction
			12.6.1.1 Polyvinyl Chloride
			12.6.1.2 Polypropylene
			12.6.1.3 ABS
			12.6.1.4 Polyamide
			12.6.1.5 Polystyrene
			12.6.1.6 Polyoxymethylene (POM)
			12.6.1.7 Polycarbonate
			12.6.1.8 Polyethylene
		12.6.2 Conclusion
		12.6.3 Review Questions
Multiple Choice Questions (MCQs) With Answers and Necessary Explanation
	Chapter 1: Automotive Materials
	Chapter 2: Nonferrous Materials
	Chapter 3: Heat Treatment
	Chapter 4: Moulding and Casting
	Chapter 5: Forging Process
	Chapter 6: Welding Process
	Chapter 7: Material Removal Processes
	Chapter 8: Plastic Processing in the Automotive Industry
	Chapter 9: Powder Metallurgy
	Chapter 10: Surface Treatment
	Chapter 11: Press Shop Process
	Chapter 12: Case Studies of Automotive Manufacturing
Bibliography
Index