制造技术—铸造、成形和焊接（英文·原书第2版）PDF电子书下载

1.Introduction 1

1.1 Manufacturing Processes 2

1.2 Breakeven Analysis 3

References 8

Questions 8

Problems 8

part A ENGINEERING MATERIALS AND THEIR PROPERTIES 13

2.Engineering Properties and Their Measurement 13

2.1 Strength 13

2.2 Hardness 14

2.3 Ductility 18

2.4 Toughness 19

References 20

Indian Standards 20

Questions 21

3.Ferrous Materials 22

3.1 Iron 23

3.2 Structure of Materials 23

3.3 Plain Carbon Steels 27

3.4 Iron Carbon Equilibrium Diagram 29

3.5 Cast Irons 31

3.6 Other Alloying Elements 32

3.7 Steel Designation 35

References 37

Indian Standards 38

Questions 38

4.Non-Ferrous Materials 40

4.1 Aluminium 40

4.2 Copper 41

4.3 Other Materials 42

References 43

Indian Standards 43

Questions 44

5.Heat Treatment of Metals 45

5.1 Transformation Curves 45

5.2 Hardening 47

5.3 Tempering 50

5.4 Annealing and Normalising 52

5.5 Case Hardening 53

5.6 Heat Treatment of Non-Ferrous Alloys 55

References 56

Indian Standards 56

Questions 56

part B METAL CASTING PROCESSES 61

6.Metal Casting Processes 61

6.1 History 61

6.2 Advantages and Limitations 62

6.3 Applications 62

6.4 Casting Terms 62

6.5 Sand Mould Making Procedure 64

References 65

Indian Standards 65

Questions 65

7.Patterns 67

7.1 Pattern Allowances 67

7.2 Core Prints 73

7.3 Elimination of Details 73

7.4 Pattern Materials 74

7.5 Types of Patterns 76

7.6 Pattern Colour Code 80

References 80

Indian Standards 80

Questions 81

Problems 81

8.Moulding Materials 88

8.1 Moulding Sand Composition 89

8.2 Testing Sand Properties 91

8.3 Sand Preparation 96

8.4 Moulding Sand Properties 97

8.5 Indian Sands 102

8.6 Other Sands 104

8.7 Fluidity 107

8.8 Types of Sand Moulds 109

8.9 Moulding Machines 111

References 112

Indian Standards 112

Questions 113

Problems 114

9.Cores 115

9.1 Core Sands 116

9.2 Carbon Dioxide Moulding 116

9.3 Types of Cores 117

9.4 Core Prints 119

9.5 Chaplets 122

9.6 Forces Acting on the Moulding Flasks 123

References 124

Indian Standards 124

Questions 125

Problems 125

10.Elements of Gating Systems 126

10.1 Elements of a Gating System 127

10.2 Gates 129

10.3 Casting Yield 132

References 133

Questions 134

11.Gating System Design 135

11.1 Pouring Time 136

11.2 Choke Area 138

11.3 Sprue 141

11.4 Other Gating Elements 142

11.5 Gating Ratios 144

11.6 Slag Trap Systems 148

References 151

Questions 152

Problems 152

12.Risering Design 156

12.1 Caine’s Method 157

12.2 Modulus Method 159

12.3 Naval Research Laboratory Method 163

12.4 Feeding Distances 170

12.5 Chills 170

12.6 Feeding Aids 174

References 179

Indian Standards 180

Questions 180

Problems 180

13.Melting Practice 182

13.1 Cupola 182

13.2 Charge Calculations 185

13.3 Other Furnaces 188

13.4 Ladles 189

References 190

Indian Standards 191

Questions 191

Problems 191

14.Casting Cleaning and Casting Defects 194

14.1 Fettling 195

14.2 Defects in Castings 195

References 198

Questions 198

15.Product Design for Sand Castings 200

15.1 Designing for Economical Moulding 200

15.2 Designing for Eliminating Defects 203

15.3 Features to Aid Handling 210

References 211

Questions 211

16.Special Casting Processes 214

16.1 Shell Moulding 214

16.2 Precision Investment Casting 217

16.3 Permanent Mould Casting 219

16.4 Die Casting 220

16.5 Centrifugal Casting 225

16.6 Continuous Casting 227

References 227

Indian Standards 230

Questions 230

part C METAL FORMING PROCESSES 233

17.Metal Forming Processes 233

17.1 Nature of Plastic Deformation 233

17.2 Hot Working and Cold Working 234

References 238

Questions 239

18.Rolling 240

18.1 Principle 240

18.2 Rolling Stand Arrangement 242

18.3 Rolling Load 244

18.4 Roll Passes 245

18.5 Breakdown Passes 246

18.6 Roll Pass Sequences 248

References 250

Indian Standards 253

Questions 253

19.Forging 254

19.1 Forging Operations 254

19.2 Smith Forging 255

19.3 Drop Forging 255

19.4 Press Forging 257

19.5 Machine Forging 257

19.6 Forging Defects 258

19.7 Forging Design 259

19.8 Drop Forging Die Design 265

19.9 Upset Forging Die Design 272

References 280

Indian Standards 281

Questions 281

20.Extrusion and Other Processes 284

20.1 Extrusion Principle 284

20.2 Hot Extrusion Processes 286

20.3 Cold Extrusion 287

20.4 Tooling for Cold Extrusion 289

20.5 Extruding Tubes 290

20.6 Wire Drawing 292

20.7 Rod and Tube Drawing 294

20.8 Swaging 295

20.9 Tube Making 296

References 297

Questions 298

21.Sheet Metal Operations 299

21.1 Press Tool Operations 299

21.2 Shearing Action 300

21.3 Shearing Operations 303

21.4 Drawing 309

21.5 Draw Die Design 311

21.6 Spinning 317

21.7 Bending 317

21.8 Stretch Forming 321

21.9 Embossing and Coining 322

References 323

Questions 323

Problems 324

22.Sheet Metal Die Design 327

22.1 Types of Dies 327

22.2 Die Construction 329

22.3 Punch Design 333

22.4 Pilots 340

22.5 Stripper and Stock Guide 342

22.6 Die Stops 344

22.7 Stock Strip Layout 346

22.8 Component Design for Blanking 349

22.9 Strip Development 350

22.10 Centre Line of Pressure 354

References 355

Indian Standards 355

Questions 356

part D METAL FABRICATION PROCESSES 361

23.Introduction to Fabrication Processes 361

23.1 Classification 361

23.2 General Considerations 362

References 366

Indian Standards 366

Questions 366

24.Gas Welding and Cutting 368

24.1 Principle 368

24.2 Oxy-Acetylene Welding Equipment 370

24.3 Oxy-Acetylene Welding Technique 371

24.4 Oxy-Hydrogen Welding 373

24.5 Gas Cutting 374

References 377

Indian Standards 377

Questions 378

25.Electric Arc Welding 379

25.1 Principle of Arc 379

25.2 Arc Welding Equipment 380

25.3 Electrodes 382

25.4 Manual Metal Arc Welding 384

25.5 Carbon Arc Welding 392

25.6 Inert Gas Shielded Arc Welding 393

25.7 Tungsten Inert Gas Welding （TIG） 394

25.8 Gas Metal ArcWelding （GMAW） 398

25.9 Submerged Arc Welding （SAW） 407

25.10 Other Arc Welding Processes 412

25.11 Arc Cutting 415

References 415

Indian Standards 416

Questions 417

26.Resistance Welding 419

26.1 Principle 419

26.2 Resistance Spot Welding 422

26.3 Resistance Seam Welding 425

26.4 Projection Welding 425

26.5 Upset Welding 428

26.6 Flash Welding 428

References 428

Indian Standards 429

Questions 429

27.Other Welding Processes 430

27.1 Thermit Welding 430

27.2 Electro Slag Welding 431

27.3 Electron Beam Welding 432

27.4 Laser Beam Welding 434

27.5 Forge Welding 435

27.6 Friction Welding 435

27.7 Diffusion Welding 436

27.8 Explosion Welding 437

References 437

Questions 438

28.Welding Design 439

28.1 Heat Input 439

28.2 Heat Flow 441

28.3 Distortions 446

28.4 Defects in Welding 451

References 454

Questions 454

Problems 454

29.Brazing, Braze Welding and Soldering 456

29.1 Brazing 456

29.2 Braze Welding 457

29.3 Soldering 458

References 459

Indian Standards 459

Questions 459

Appendix SI Units 461

Index 465