Principles of metal manufacturing processes

Front Cover......Page 1
Principles of Metal Manufacturing Processes......Page 4
Copyright Page......Page 5
Contents......Page 6
Preface......Page 9
1.2 The manufacturing engineering discipline......Page 12
1.3 Materials used in manufacturing......Page 14
1.5 Primary manufacturing processes – steelmaking......Page 15
1.6 Primary manufacturing processes – aluminium production......Page 23
1.7 Secondary manufacturing......Page 26
1.8 Problems......Page 27
2.2 Major casting techniques......Page 29
2.3 Solidification mechanism......Page 41
2.4 Solidification volume shrinkage......Page 47
2.5 Heat transfer during solidification......Page 51
2.6 Defects produced during casting......Page 60
2.7 Shape casting materials......Page 68
2.8 Design of shape castings for manufacturing......Page 72
2.9 Problems......Page 74
Case study 1: Manufacture of can body stock – 1. Casting......Page 78
Case study 2: Cosworth–Ford casting process......Page 83
3.2 Engineering stress–strain......Page 87
3.3 True stress and true strain......Page 91
3.4 Relationship between engineering and true stress–strain......Page 97
3.5 Deformation work......Page 99
3.7 Hot deformation......Page 102
3.8 Superplasticity......Page 106
3.9 Problems......Page 107
4.1 Introduction......Page 110
4.2 Friction during bulk deformation......Page 111
4.3 Forging......Page 114
4.4 Extrusion......Page 126
4.5 Drawing......Page 132
4.6 Rolling......Page 133
4.7 Analytical methods for bulk deformation processes......Page 143
4.8 Problems......Page 146
Case study 3: Manufacture of can body stock – 2. Rolling......Page 149
5.2 Formability......Page 153
5.3 Shearing......Page 155
5.4 Bending......Page 157
5.5 Stretch forming......Page 161
5.6 Deep drawing......Page 163
5.7 Effect of anisotropic sheet properties on formability......Page 169
5.9 Problems......Page 173
Case study 4: Manufacture of can body stock – 3. Sheet forming......Page 177
6.1 Introduction......Page 184
6.2 Powder production......Page 186
6.3 Powder characteristics......Page 191
6.4 Powder compaction......Page 192
6.5 Metal injection moulding......Page 198
6.6 Problems......Page 199
7.1 Introduction......Page 201
7.2 Mechanical machining methods......Page 202
7.3 Nontraditional machining processes......Page 234
7.4 Comparison of methods......Page 239
7.5 Problems......Page 240
8.2 Welding......Page 243
8.3 Brazing......Page 274
8.5 Problems......Page 278
Case study 5: Processing to produce automobile radiators......Page 281
Case study 6: Manufacture of stainless steel automotive exhaust systems......Page 286
9.1 Introduction......Page 290
9.2 Types of wear......Page 291
9.3 Diffusional processes......Page 296
9.4 Flame and induction hardening......Page 308
9.5 Plating processes......Page 311
9.6 Thin film coatings......Page 314
9.7 Problems......Page 317
Appendix A: Useful constants......Page 320
Appendix B: Useful conversion factors......Page 321
Appendix C: Hardness conversion......Page 323
Index......Page 324