Materials and Manufacturing Processes

113 Pages·2019·2.377 MB·English

by  Kaushik Kumar, Hridayjit Kalita, Divya Zindani, J. Paulo Davim

Materials Forming, Machining and Tribology
Kaushik Kumar
Hridayjit Kalita
Divya Zindani
J. Paulo Davim
Materials and
Manufacturing
Processes
Materials Forming, Machining and Tribology
Series Editor
J. Paulo Davim, Department of Mechanical Engineering, University of Aveiro,
Aveiro, Portugal
This series fosters information exchange and discussion on all aspects of materials
forming, machining and tribology. This series focuses on materials forming and
machining processes, namely, metal casting, rolling, forging, extrusion, drawing,
sheet metal forming, microforming, hydroforming, thermoforming, incremental
forming, joining, powder metallurgy and ceramics processing, shaping processes
for plastics/composites, traditional machining (turning, drilling, miling, broaching,
etc.), non-traditional machining (EDM, ECM, USM, LAM, etc.), grinding and
others abrasive processes, hard part machining, high speed machining, high
efficiency machining, micro and nanomachining, among others. The formability
and machinability of all materials will be considered, including metals, polymers,
ceramics,composites,biomaterials,nanomaterials,specialmaterials,etc.Theseries
covers the full range of tribological aspects such as surface integrity, friction and
wear, lubrication and multiscale tribology including biomedical systems and
manufacturing processes. It also covers modelling and optimization techniques
applied in materials forming, machining and tribology. Contributions to this book
series are welcome on all subjects of “green” materials forming, machining and
tribology. To submit a proposal or request further information, please contact Dr.
MayraCastro,PublishingEditorAppliedSciences,[email protected]
or Professor J. Paulo Davim, Book Series Editor, via [email protected]
More information about this series at http://www.springer.com/series/11181
Kaushik Kumar Hridayjit Kalita
(cid:129) (cid:129)
Divya Zindani J. Paulo Davim
(cid:129)
Materials and Manufacturing
Processes
123
Dr. KaushikKumar Dr. Hridayjit Kalita
Department ofMechanical Engineering Department ofMechanical Engineering
Birla Institute of Technology Birla Institute of Technology
Ranchi, Jharkhand, India Ranchi, Jharkhand, India
DivyaZindani Prof. J.PauloDavim
Department ofMechanical Engineering Department ofMechanical Engineering
National Institute ofTechnology Silchar University of Aveiro
Silchar, Assam, India Aveiro, Portugal
ISSN 2195-0911 ISSN 2195-092X (electronic)
Materials Forming,Machining andTribology
ISBN978-3-030-21065-6 ISBN978-3-030-21066-3 (eBook)
https://doi.org/10.1007/978-3-030-21066-3
©SpringerNatureSwitzerlandAG2019
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Preface
The authors are pleased to present the book Materials and Manufacturing
Processes under Book Series Materials Forming, Machining and Tribology. This
book would serve as an initial part of the book Advanced Machining and
Manufacturing Processes (ISBN 978-3-319-76074-2), under the same series and
also published by Springer International Publishing AG. These books together
would provide readers a complete picture of manufacturing technology starting
from materials to virtual manufacturing covering the basic and advanced aspects.
This book, the preamble of the two, has been written with a view to project the
basic understanding of the materials and traditional processes involved in a man-
ufacturing industry. The properties and application of different engineering mate-
rialshavebeendiscussedandfailuretestsperformedontheworkmaterialsofboth
destructible and non-destructible in nature have been explained in detail. The
processes and the design associated with manufacturing processes like casting,
forming, welding, machining, etc. have been covered in a simple and lucid lan-
guage. The main emphasis, hence, is directed towards industrial engineering out-
look. The target audience is academics students, researchers and industry
practitioners,engineers, research scientists/academicians working inthis vast field.
This book is divided into three parts ranging from engineering materials to
various basic manufacturing and machining processes that may be employed by
manufacturingindustriesforbetterunderstandingoftheintricaciesofthesystemto
improvetheiroutputtowardsabettersocio-economicdevelopment.Asthesections
are independent of each other, in each part, chapters are independently numbered.
PartIdealswithEngineeringMaterials.Thepartcontainstwochapters.Chapter1
deals with Introduction to Materials. There has been a major development in the
material research and applications in industrial and commercial components or
products.Withtheincreaseindemandofcustomersforvariouscustomizedproducts
thereisneedtobedurable,functionallyreliableandlowcostatthesametime.These
requirementsmotivatedesignersandmanufacturerstotacklethechallengingtaskof
optimizingthecontrolfactorsthatdeterminethequalityofthefinalproduct.Inthis
chapter,theproperties,compositions and characteristics ofdifferent materials have
beendescribedindetailundertheheadingofallengineeringmaterialsusedpresently
v
vi Preface
in industries and structural works. The production procedure of these materials,
processesforheattreatmentsforalteringpropertiesofthematerialandapplications
ofthesematerialsaredescribedindetailinthischapter.
Chapter 2 explores Mechanical Behaviour of Materials. Material is the most
important aspect of research in all engineering domains which gives an under-
standing of the real physical structure of various products and objects that are
availableallaround.Thebehaviourofthesevariousproductsintheirservicelifeis
very important to analyse as it might not be desirable to have a product fail at the
most unexpected time. In order to quantify these behaviors of material, various
properties, as described, in the earlier chapter are determined by running material
tests.Theprocedureforcarryingoutthesetests,feasibilityofthesetesttobeableto
runfordifferentmaterialsandthebehaviouroftheparttobetestedaresomeofthe
aspectswhichhavebeenexplainedindetailinthischapter.Materialtestshavebeen
detailed in two major branches namely, destructible and non destructible tests.
Some other fracture surface behaviour in ductile and brittle material upon appli-
cation of loads higher than their fracture strength and responses for plastic defor-
mation in the form of heat generation and build up of residual stresses are also
described in this chapter. This ends Part I.
PartIIcontainingthreechapterscoversConventionalManufacturing.Chapter3
of this section elaborates Casting, the most widely used manufacturing process.
Herethebasicunderstandingofthecastingprocess,operationsanddesigninvolved
in the sand mould casting process, various metal mould casting processes and few
other commonly used casting processes are described in detail.
Chapter 4 of this section deals with Forming Process. Right from the advent of
industrialrevolution,thishasbeenthemostimportantandversatileoperationinany
manufacturingandmetalworkingindustries.Metalsareneededtobedeformedfor
avarietyoffunctionalrequirementsintheproductorforenhancingthestrengthand
hardness.Thisdeformationproducesacomplexflowofmaterialwhichbasicallyis
dependentontheamountofforceapplication,ductilityofthematerial,temperature
of the material and modulus of elasticity. Deformation can be in the form of bulk
deformation under compressive loads or bending, stretching, shrinking or shearing
inthe sheet metal operations based on which different tools(rollers in rolling, dies
and punch) have to be designed accordingly for operations such as blanking,
extrusion, wire drawing, rolling, etc. The temperature of the metal has to be
maintained such that sufficient plasticity is induced and can be operated with the
given capacity of the machine. Few positive aspects offorming processes include
insignificant wastage of material, high output material strength, dimensional
accuracy and simpler mechanism.
Chapter 5, the last chapter of the section, discusses another very important
manufacturingprocessi.e.Welding.Itisaprocesswhichenableslargeandcomplex
shaped products to be divided into small and simple parts to be manufactured
independently and later can be rigidly joined by fusion of the material at the
interface between two metal pieces, stiff enough to operate as a single piece.
Welding process is mainly characterized by the melting of the interface material
between the two metals, fusion or mixing of the material and then solidifying to
Preface vii
producearigidandhighstrengthjoint.Insomecasesorapplications,evenanaxial
or shear pressure may accompany the fusion phenomenon to trigger a plastic
deformation of material at the interface for tight bonding. In this chapter, the
fundamental concept behind the various welding processes and how are these
classifiedbasedondifferentheatsourceutilizationandtechniquesofutilizationare
explained in detail.
The last section of the book Part III focuses on Conventional Machining and
containsasinglechapter,Chap.6.Allmetalparts,afterbeingcastedorformedhas
to be shaped into its final dimensions so that it could meet the required function-
ality, durability and aesthetic characteristics of a product. This chapter elaborates
the shaping process which requires metal removal involving various complex
phenomenon and factors and a set of mechanisms that can be controlled by con-
sidering various tool geometry, optimized cutting conditions and better tool–work
material combination. In this chapter processes like turning, milling, boring, dril-
ling, reaming, planning and shaping, sawing, filing, broaching, etc have been dis-
cussed in detail.
Augmentation of this introductory book along with Advanced Machining and
Manufacturing Processes (ISBN 978-3-319-76074-2), published by Springer
International Publishing AG would provide, all readers, complete domain of
manufacturing world.
First and foremost we would like to thank God for providing the power of
thinking and means of expression. We would like to thank all of our colleagues,
friends in different part of the world for sharing of ideas in shaping our thoughts.
WeoweahugethankstoallofourTechnical reviewers,EditorialAdvisoryBoard
Members,BookDevelopmentEditorandtheteamofPublisherSpringerNaturefor
their availability to work on this huge project. All of their efforts helped to make
this book complete and we could not have done it without them.
Throughout the process of writing this book, many individuals, from different
walks of life, have taken time out to help us out. Last, but definitely not least, we
wouldliketothankthemall,ourwellwishers,forprovidingusencouragement.We
would have probably given up without their support.
Ranchi, India Kaushik Kumar
Ranchi, India Hridayjit Kalita
Assam, India Divya Zindani
Aveiro, Portugal J. Paulo Davim
Contents
Part I Engineering Materials
1 Introduction to Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 Highlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.3 Ferrous Metals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.3.1 Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.3.2 Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3.3 Processes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.3.4 Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.4 Non Ferrous Metal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.4.1 Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.4.2 Properties and Applications . . . . . . . . . . . . . . . . . . . . . . 11
1.4.3 Heat Treatment Processes in Non Ferrous Metals. . . . . . . 13
1.5 Ceramic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.6 Polymers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.7 Composites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.8 Graphite and Diamond . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.9 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2 Mechanical Behaviour of Materials . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.1 Highlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.2 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.3 Destructible Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.3.1 Tensile Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.3.2 Compression Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.3.3 Hardness Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.3.4 Fatigue Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
ix
x Contents
2.3.5 Creep Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.3.6 Impact Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.4 Non Destructible Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.4.1 Visual Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.4.2 Radiography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.4.3 Ultrasonic Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.4.4 Magnetic Particle Test . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.4.5 Eddy Current Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.4.6 Acoustic Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.4.7 Liquid Penetration Method . . . . . . . . . . . . . . . . . . . . . . . 31
2.5 Failure Characteristics in Materials . . . . . . . . . . . . . . . . . . . . . . . 31
2.5.1 Fracture Types. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.5.2 Plastic Deformation Responses . . . . . . . . . . . . . . . . . . . . 32
2.6 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Part II Conventional Manufacturing
3 Casting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3.1 Highlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3.2 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3.3 Fundamentals of Casting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3.3.1 Solidification of Metal . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3.3.2 Fluidity of Molten Metal . . . . . . . . . . . . . . . . . . . . . . . . 40
3.3.3 Pouring Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3.4 Sand Mould Casting Process. . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3.4.1 Pattern Making . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3.4.2 Mould Making. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
3.4.3 Core Making . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
3.4.4 Casting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3.5 Metal Mould Casting Process . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3.5.1 Slush Casting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3.5.2 Die Casting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3.5.3 Centrifugal Casting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3.5.4 Continuous Casting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3.6 Investment Mould Casting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
3.7 Plaster Mould Casting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
3.8 Ceramic Mould Casting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
3.9 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
4 Forming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
4.1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
4.2 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53