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INDIA
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(manufacturing processes)
Thirteenth edition 2003
S.K. HAJRA CHOUDHURY
A.K. HAJRA CHOUDHURY
NIRJHAR ROY
1.General introduction 01-18
1. Manufacturing processes, 1 ; 2. Classification of manufacturing processes, 1 ; 3. Types of production system, 3 ; 4. Plant layout, 3 ; 5. Objective of plant layout, 3 ; 6. Types of layout, 4 ; 7. Product design, 10 ; 8. Process selection, 12 ; 9. Industrial safety, 12 ; 10. Factories act and accidents, 16.
2.Fundamental of metals and alloys 19--40
1. Introduction, 19 ; 2. Atom, 19 ; 3. Structure of solids, 20 ; 4. Formation of grains, 23 ; 5. Imperfections in crystals, 25 ; 6. Deformation of metals, 26 ; 7. Property changes by deformation, 29 ; 8. Recovery, recrystallization and grain growth, 30 ; 9. Fracture, 32 ; 10. Metal alloys, 33 ; 11. Solidification of an alloy, 33 ; 12. Equilibrium diagrams, 36 ; 13. Iron-carbon equilibrium diagram, 37.
3.Properties, testing & inspection of metals 41-60
1. Introduction, 41 ; 2. Stress and strain, 41 ; 3. Mechanical properties, 42 ; 4. Testing of metals, 47 ; DESTRUCTIVE TESTING, 47 ; 5. Tensile testing, 47 ; 6. Compression test, 50 ; 7. Hardness tests, 50 ; 8. Impact testing, 54 ; 9. Fatigue testing, 55, 10. Creep and stress rupture testing, 56 ; 11. Nondestructive testing, 57.
4. Ferrous metals and alloy 61-102
1. Introduction, 61 ; 2. Pig iron, 61 ; 3. Modern development, 63 ; 4. Cast iron, 64 ; 5. Wrought iron, 70 ; 6. Effect of chemical elements on iron, 73 ; 7. Steels, 74 ; 8. Steel making processes, 75 ; 9. The Bessemer process, 75 ; 10. The L-D process, 76 ; 11. The open hearth process, 77 ; 12. The crucible process, 79 ; 13. The electric furnace process, 79 ; 14. Duplex processes, 82 ; 15. Classification of steels, 82 ; 16. Applications of carbon steels, 84 ; 17. Influence of the constituents on steel, 84 ; 18. Bright steels, 86 ; 19. Free cutting steels, 86 ; 20. Alloy steel, 87 ; 21. Classification of alloy steels, 88 ; 22. Special alloy steels, 90 ; 23. Cutting alloys, 94 ; 24. Coding of iron and steel, 95 ; 25. Comparison of Indian and overseas standards, 101 ; 26. Classification of steels by SAE and AISI, 101.
5.Nonferrous metals and alloys 103-118
1. Introduction, 103 ; 2. Aluminium and its alloys, 103 ; 3. Copper and its alloys, 105 ; 4. Lead and its alloys, 107 ; 5. Tin, 108 ; 6. Bearing metals, 108 ; 7. Copper-tin-antimony alloy, 109 ; 8. Copper-tin alloy, 109 ; 9. Zinc and its alloys, 111 ; 10. Copper-zinc alloy, 111 ; 11. Nickel and its alloys, 112 ; 12. Alloys for high temperature service, 115 ; 13. Metals for nuclear energy, 115.
6.Heat treatment of metals and alloys
119-152
1. Introduction, 119 ; 2. Cooling curve for pure iron, 119 ; 3. Inverse-rate curves for steel, 120 ; 4. Transformation in steel, 121 ; 5. Purposes and methods of heat treatment, 125 ; 6. Annealing, 126 ; 7. Normalizing, 130 ; 8. Hardening, 131 ; 9. Martempering, 132 ; 10. Austempering, 133 ; 11. Hardenability, 133 ; 12. Tempering, 135 ; 13. Case hardening : carburising, 137 ; 14. Cyaniding, 138 ; 15. Nitriding, 139 ; 16. Induction hardening, 139 ; 17. Flame hardening, 140 ; 18. Diffusion coating, 140 ; 19. Heat treatment of aluminium, 140 ; 20. Heat-treatment of cutting tools, 143 ; 21. Heat-treating furnaces, 144 ; 22. Hearth furnaces, 145 ; 23. Bath furnaces, 146 ; 24. Furnace temperatures, 148.
7.Mechanical working of metals 153 -170
1. Introduction, 153 ; 2. Hot working, 153 ; 3. Hot rolling, 154 ; 4. Piercing or seamless tubing, 157 ; 5. Drawing, 157 ; 6. Deep Drawing. 158 ; 7. Hot spinning, 158 ; 8. Extrusion, 159 ; 9. Cold-working, 161 ; 10. Cold-rolling, 162 ; 11. Cold-drawing, 162 ; 12. Cold-bending, 164 ; 13. Cold-spinning, 165 ; 14. Cold-extrusion, 166 ; 15. Squeezing, 166 ; 16. Peening, 167 ; 17. Sizing, coining and hobbing, 167 ; 18. Electro-hydraulic forming, 168 ; 19. Metallurgical aspects, 169.
8. Smithing and forging 171--210
1. Introduction, 171 ; 2. Forging materials, 171 ; 3. Heating devices, 172 ; 4. Forging temperatures, 175 ; 5. Hand tools and appliances, 177 ; 6. Smith forging operations, 179 ; 7. Smith forging examples, 183 ; 8. Forging processes, 187 ; 9. Hand forging, 188 ; 10. Power forging, 189 ; 11. Impression-die forging, 193 ; 12. Drop hammers, 196 ; 13. Press forging, 197 ; 14. Roll die forging, 199 ; 15. Press vs. hammer forging, 200 ; 16. Machine or upset forging, 201 ; 17. High energy-rate forging (HERF), 202 ; 18. Fibrous structure of forgings : grain-flow, 203 ; 19. Effects of forging : forged parts vs. cast parts, 204 ; 20. Defects in forging, 205 ; 21. Heat treatment of forged parts, 206 ; 22. Design considerations, 207 ; 23. Advantages and limitations, 208.
9. Welding and related processes 211-268
1. Introduction, 211 ; 2. Weldability, 211 ; 3. Types of welding, 213 ; 4. Metallurgy of weld, 213 GAS WELDING, 215 ; 5. Oxy-acetylene welding, 215 ; 6. Air-acetylene welding, 223 ; 7. Oxy-hydrogen welding, 224 ; ARC WELDING, 224 ; 8. Metal transfer in arc welding, 226 ; 9. Arc welding equipment, 227 ; 10. Arc welding methods, 233 ; RESISTANCE WELDING, 241 ; 11. Resistance welding methods, 242 ; 12. Thermit welding, 246 ; SOLID STATE WELDING, 247 ; 13. Solid-state welding methods, 247 ; NEWER WELDING METHODS, 250 ; 14. Newer types of welding (Electron beam welding, laser-beam welding), 250 ; RELATED PROCESSES, 252 ; 15. Oxygen cutting, 252 ; 16. Hard facing, 255 ; 17. Bronze welding, 256 ; 18. Soldering, 256 ; 19. Brazing, 258 ; 20. Welding of various metals, 258 ; 21. Inspection and testing of welds, 261 ; 22. Welded joints and edge preparation, 262 ; 23. Welding of pipes, 264 ; 24. Representation of welds (Indian Standard), 266.
10.Wood and wood working 269-306
1. Introduction, 269 ; 2. Structure of wood, 269 ; 3. Grain in wood, 270 ; 4. Seasoning of wood, 271 ; 5. Classification of wood, 272 ; 6. Conversion, 273 ; 7. Common varieties of Indian timber, 273 ; 8. Carpentry tools, 274 ; 9. Marking and measuring tools, 274 ; 10. Cutting tools, 277 ; 11. Planes, 281 ; 12. Boring tools, 284 ; 13. Striking tools, 286 ; 14. Holding tools, 287 ; 15. Miscellaneous tools, 289 ; 16. Setting and sharpening of tools, 290 ; 17. Carpentry processes, 292 ; 18. Marking, 292 ; 19. Sawing, 293 ; 20. Planing, 293 ; 21. Chiselling, 294 ; 22. Boring, 294 ; 23. Grooving, 295 ; 24. Rebating, 295 ; 25. Moulding, 295 ; 26. Carpentry joints, 296 ; 27. Woodworking machines, 301.
11.Patternmaking and foundry 307- 430
1. Introduction, 307 ; 2. Pattern materials, 307 ; 3. Patternmaking tools, 311 ; 4. Types of patterns, 312 ; 5. Patternmaking allowances, 320 ; 6. Methods of constructing patterns, 322 ; 7. Other technological considerations, 326 ; 8. Coreprints, 328 ; 9. Core boxes, 329 ; 10. Colour coding for patterns and core boxes, 331 ; FOUNDRY, 332 ; 11. Moulding tools and equipment, 332 ; 12. Moulding sands, 337 ; 13. Types of moulding sand, 341 ; 14. Grain shape and size of sand, 342 ; 15. Sand additives, 343 ; 16. Properties of moulding sand, 345 ; 17. Sand preparation, 346 ; 18. Sand testing, 348 ; 19. Moulding processes, 352 ; 20. Moulding processes based on sand used, 352 ; 21. Making a green-sand mould, 357 ; 22. Typical moulding problems, 359 ; 23. Moulding processes based on the methods used, 362 ; 24. Machine moulding, 364 ; 25. Cores and core making, 368 ; 26. Special moulding processes, 374 ; CO2 moulding, Ferro-sillicon moulding, Dicalcium silicate moulding, Cement-sand moulding, Shell moulding, Hot- and cold-box moulding, Investment mould-process, Plaster moulding, Ceramic moulding, 27. Permanent mould casting, 386 ; Slush casting, Die casting, Centrifugal casting, Continuous casting, 28. Gating and risering of castings, 392 ; 29. Risering of castings, 400 ; 30. Use of padding and chills, 402 ; 31. Melting furnaces for ferrous metals : Cupola, 403 ; 32. Melting furnaces for nonferrous metals, 414 ; 33. Ladles, 416 ; 34. Pouring the metal, 417 ; 35. Cleaning of castings, 418 ; 36. Defects in castings, 419 ; 37. Inspection and quality control, 422 ; 38. Modernization and mechanization of foundries, 423 ; 39. Design of casting, 425.
12. Powder metallurgy 431-440
1. Introduction, 431 ; 2. Process description, 431 ; 3. Manufacture of metal powders, 432 ; 4. Blending of powders, 433 ; 5. Compacting, 434 ; 6. Presintering, 434 ; 7. Sintering, 434 ; 8. Secondary operations, 435 ; 9. Isostatic pressing, 436 ;10. Products of powder metallurgy, 437 ; 11. Advantages of the process, 438 ; 12. Disadvantages and limitations, 438 ; 13. Design consideration, 439 ;
VOL-II
(machine tools)
S.K. HAJRA CHOUDHURY
S.K BOSE
A.K. HAJRA CHOUDHURY
NIRJHAR ROY
1 Transmission of motionand power
2. Metal cutting and cutting tools
3. The lathe
4. Capstan and turret lathes
5. Drilling machine
6. Boring machines
7. Shaper
8. Planing machines
9. Slotting machines
10. Grinding machines
11. Milling machines
12. Gear cutting
13. Press and presswork
14. Jigs and fixtures
15. Broaching and sawing
16. Surface finishing processes
17. Erecting and testing machine tools
18. Kinematic design of machine tools
19. Numerical control of machine tools
20. Non-traditional machining
21. Transfer machining
22. Process planning and cost evaluation
23. CAD, CAM and CIM
Apendix, Index
ISBN: 81-85099-15-4
INR--Rs 175/-
pp 705
1. Introduction, 441 ; 2. Types of plastics, 441 ; 3. Elastomers, 446 ; 4. Materials for processing plastics, 446 ; PROCESSING PLASTICS, 447 ; 5. Moulding processes, 448 ; 6. Calendering, 452 ; 7. Thermoforming, 452 ; 8. Casting, 454 ; 9. Laminating and reinforcing, 454 ; 10. Foamed plastics, 455 ; 11. Fastening machining plastics, 455 ; 12. Design considerations, 457.
14.Bench work and fitting 459-494
1. Introduction, 459 ; 2. Vices, 460 ; 3. Hammers, 462 ; 4. Chisels, 464 ; 5. Chipping, 467 ; 6. Files, 468 ; 7. Filing, 471 ; 8. Scraper, 474 ; 9. Scraping, 475 ; 10. Grinding and polishing, 476 ; 11. Hacksaw, 477 ; 12. Sawing, 480 ; 13. Marking tools, 481 ; 14. Surface plate, 481 ; 15. Scriber, 481 ; 16. Punch, 482 ; 17. V-block, 482 ; 18. Angle plate, 483 ; 19. Try-square, 483 ; 20. Marking out, 484 ; 21. Drill, 485 ; 22. Drilling, 486 ; 23. Reamer, 487 ; 24. Reaming, 488 ; 25. Taps, 489 ; 26. Tap drill size, 490 ; 27. Tapping, 491 ; 28. Dies and stock, 492 ; 29. Dieing, 493.
15.Limits, fits and surface quality 495-518
1. Introduction, 495 ; 2. Interchangeability, 495 ; 3. Elements of interchangeable system, 496 ; 4. Fits, allowances, clearances and interferences, 499 ; 5. Types of fits, 500 ; 6. Hole basis and shaft basis, 502 ; 7. Geometric dimensioning and tolerances, 503 ; 8. Limit systems, 504 ; 9. The Indian Standard system, 504 ; 10. Selective assembly, 511 ; SURFACE QUALITY, 512 ; 11. Surface characteristics, 512 ; 12. Evaluation of surface finish, 513 ; 13. Symbols of drawings, 517.
16. Measurement and inspection 519-568
1. Introduction, 519 ; 2. Standards of measurement, 519 ; 3. Classification of measuring instruments, 521 ; 4. Linear measurement (nonprecision), 522 ; 5. Linear measurement (precision), 526 ; 6. Comparators, 539 ; 7. Measuring machines, 545 ; 8. Angular measurement, 545 ; 9. Taper measurement, 554 ; 10. Surface measurement, 555 ; 11. Use of LASER, 559 ; 12. Gauges, 560.
17.Surface coating of metals 569-590
1. Introduction, 569 ; CLEANING OF METALS, 569 ; 2. Chemical cleaning, 570 ; 3. Mechanical cleaning, 573 ; FINISHES OF METALS, 576 ; 4. Metallic coatings, 576 ; 5. Plastic coating, 583 ; 6. Organic finishes, 585 ; 7. Inorganic coatings, 588.
18.Sheet metal work 591-608
1. Introduction, 591 ; 2. Metals used in sheet metal work, 591 ; 3. Sheet metal hand tools, 593 ; 4. Sheet metal operations, 597 ; 5. Sheet metal joints : Hems and seams, 600 ; 6. Sheet metal allowance, 601 ; 7. Sheet metal working machines, 602 ; 8. Laying out a pattern, 603.
19.Plumbing, threading fasteners and joints
609-622
1. Plumbing, 609 ; 2. Specification of pipes, 609 ; 3. Material used for pipes, 609 ; 4. Pipe fitting and joints, 610 ; 5. Taps and valves, 611 ; 6. Plumber’s tools, 612 ; 7. Threaded fasteners, 613 ; 8. Screw threads and their uses, 614 ; 9. Indian Standard threads, 615 ; 10. Cap screws and machine screws, 616 ; 11. Set screws, 617 ; 12. Methods of producing screw threads, 617 ; 13. Bolts, 617 ; 14. Studs, 618 ; 15. Forms of nuts, 618 ; 16. Reveting joints, 620.
20.Quality control 623-642
1. Introduction, 623 ; 2. Inspection and quality control, 623 ; 3. Statistical quality control, 624 ; 4. Fundamental of statistics, 625 ; 5. Control charts, 629 ; 6. Control charts for variables, 630 ; 7. Control charts for attributes, 634 ; 8. Control charts for defects, 637 ; 9. Application of control charts, 639 ; 10. Sampling inspection, 639.
21.Introduction to Machine Tool 643-655
Appendix Index
ISBN 81-85099-14-6
pp 670
INR- Rs 180/-
