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Manufacturing Technology دار جامعة عدن للطباعة والنشر تصدر سلسلة الكتاب الجامعي 2-2017 بعنوان

الخميس - 11 يناير 2018 - 09:50 ص بتوقيت عدن

 Manufacturing Technology دار جامعة عدن للطباعة والنشر تصدر سلسلة الكتاب الجامعي 2-2017 بعنوان



أصدرت دار جامعة عدن للطباعة والنشر سلسلة الكتاب الجامعي 2-2017 بعنوان  Manufacturing Technology



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CONTENTS

 
Page No
CONTENTS
I-VI
PREFACE
 
INTRODUCTION
1 - 2
CHAPTER I - ENGINEERING  MATERIALS
3 - 32
I.1. Introduction
3
I.2. Classification of engineering materials
4
I.3. Non-metals
4
  I.3. 1. Organic non-metals
6
  I.3. 2. Inorganic materials
6
I.4. Metals
6
  I.4. 1. Non-ferrous metals/alloys
8
  I.4. 2. Ferrous metals alloys
9
  I.4. 2.1. Pure iron
9
  I.4. 2. 2. Pig iron
10
  I.4. 2. 3. Wrought iron
10
  I.4. 2. 4. Cast iron
11
  I.4. 2. 4. 1. Grey cast iron
11
  I.4. 2. 4. 2. White cast iron
11
  I.4. 2. 4. 3. Malleable cast iron
12
  I.4. 2. 5. Steel
12
   I.4. 2. 5. 1. Carbon steel
13
  I.4. 2. 5. 2. Alloy steel
13
  I.4. 2. 5. 2. 1. Stainless steel
13
   I.4. 2. 5. 2. 2. Tool steel
13
  I.4. 2. 5. 2. 2. 1. High speed steel
13
  I.4. 2. 5. 2. 2. 2. Heat- and rust resisting steel
14
I.5. Properties of engineering materials
14
  I.5. 1. Thermal properties
14
  I.5. 2. Electrical properties
15
  I.5. 3. Magnetic properties 
15
  I.5. 4. Chemical properties
16
  I.5. 5. Optical properties
16
  I.5. 6. Physical properties
16
  I.5. 7. Mechanical properties
17
  I.5. 8. Alloying elements and their effects on mechanical properties
21
 
Page No
I. 6. Structure of steel and cast iron
25
  I. 6. 1. Solid solution
25
  I. 6. 2. Micro-constituents of steel and cast iron
26
  I. 6. 3. Iron -Carbon equilibrium phase diagram
28
 
 
CHAPTER II - EXTRACTIVE  METALLURGY
33 – 78
II. 1. Introduction
33
II. 2. Blast furnace
35
  II. 2. 1. Principle
35
  II. 2. 2. Construction
35
  II. 2. 3. Charge
38
  II. 2. 4. Operation
38
  II. 2. 5. Chemical reactions
39
II. 3. Cupola furnace
44
  II. 3. 1. Construction
44
  II. 3. 2. Operation
46
  II. 3. 3. Cupola repair
52
  II. 3. 4. Application
52
  II. 3. 5. Batching example
53
  II. 3. 6. Advantages and Disadvantages
54
II. 4. Crucible process
54
II. 5. Open - hearth furnace (Siemens-Martin-furnace)
55
  II. 5. 1. Construction
55
  II. 5. 2. Operation
56
  II. 5. 3. Open hearth similar  furnaces
58
  II. 5. 3. 1. Air furnaces
58
  II. 5. 3. 2. Non crucible furnaces 
59
II. 6. Bessemer converter
60
  II. 6. 1. Construction
60
  II. 6. 2. Operation
60
II. 7. Oxygen furnaces
63
  II. 7. 1. L-D process
63
  II. 7. 2. L.D-A.C process
65
  II. 7. 3. Kaldo process
65
II. 8. Electric furnaces
65
  II. 8. 1. Electric Arc furnaces
65
  II. 8. 1. 1. Electric Direct-arc Furnaces
65
 
Page No
  II. 8. 1. 2. Electric Indirect-arc Furnaces
68
  II. 8. 1. 3. Arc resistance furnaces
69
  II. 8. 2. Resistance furnaces
69
  II. 8. 2. 1. Direct resistance furnaces
69
  II. 8. 2. 2. Indirect resistance furnaces
69
  II. 8. 2. 3. Resistance- radiation-furnaces
70
  II. 8. 3. Induction furnaces
70
  II. 8. 3. 1. Core-type Induction Furnaces 
70
  II. 8. 3. 2. Coreless-type induction furnace
72
II. 9. Furnaces for non-ferrous metals 
74
  II. 9. 1. Coke heated furnace 
75
  II. 9. 2. Boiler furnace 
76
  II. 9. 3. Oil heated crucible furnace 
76
  II. 9. 4. Electric heated furnace 
77
 
 
CHAPTER III – CASTING 
79– 112
III. 1. Introduction 
79
III. 2. Pattern making 
79
  III. 2. 1 Pattern materials 
80
  III. 2. 2 Types of pattern 
81
III.3. Moulding sand   
82
  III. 3. 1. Classification of moulding Sand 
83
  III. 3. 2. Grain shape and size of moulding sand 
84
  III. 3. 3. Types of moulding sand 
85
   III. 3. 4.  Properties of moulding sand   
86
   III. 3. 5. Sand preparation 
89
  III. 3. 6. Sand testing   
91
  III. 3. 7. Elements of sand mould 
94
  III. 3. 8. Technology of making sand mould 
98
   III. 3. 9. Types of moulds 
100
   III. 3. 10. Core moulding 
103
   III. 3. 10. 1. Core materials 
103
  III. 3. 10. 2. Core making 
104
  III. 3. 10. 3. Types of core 
106
  III. 3. 11. Casting defects 
107





 
 
 
Page No
CHAPTER IV – METAL CUTTING
113 – 149
IV. 1. Introduction 
113
IV. 2. Metal cutting processes 
114
  IV. 2. 1 Lathe machines 
114
  IV. 2. 1. 1 Engine lathe 
114
  IV. 2. 1. 2 Other types of lathe machines 
118
  IV. 2. 1. 3 Cutting tools 
119
  IV. 2. 1. 4  Cutting conditions   
121
  IV. 2. 1. 5  Lathe operations 
122
  IV. 2. 2 Drilling 
127
   IV. 2. 2. 1 Machine tool 
128
  IV. 2. 2. 2 Cutting tool 
130
  IV. 2. 2. 3 Drilling speed and feed 
132
  IV. 2. 2. 4 Drilling operations 
132
  IV. 2. 3 Milling   
135
   IV. 2. 3. 1 Machine tool 
135
   IV. 2. 3. 1. 1 Working principle 
136
   IV. 2. 3. 1. 2 Universal milling machine 
136
  IV. 2. 3. 2 Cutting tool 
138
  IV. 2. 3. 3 Cutting conditions   
140
  IV. 2. 3. 4 Milling operations 
141
  IV. 2. 4 Shaping and planing   
143
  IV. 2. 4. 1 Machine tool 
143
  IV. 2. 4. 2 Cutting conditions 
147
  IV. 2. 4. 3 Cutting tools 
148
 
 
CHAPTER V – METAL FORMING
151 – 182
V. 1. Introduction 
151
V. 2. Mechanism of metal forming 
152
V. 3. Hot working and cold working
155
V. 4. Metal forming processes 
157
  V. 4. 1 Rolling 
157
  V. 4. 2 Pipes and tube production 
163
  V. 4. 3 Forging   
167
  V. 4. 3. 1 Smith forging 
167
  V. 4. 3. 2 Drop forging 
168
   V. 4. 3. 3 Press forging 
169
 
Page No
  V. 4. 3. 4 Upset forging 
169
  V. 4. 4 Extrusion   
169
  V. 4. 4. 1 Direct or forward extrusion
170
   V. 4. 4. 2 Indirect or backward extrusion 
170
  V. 4. 4. 3 Impact extrusion 
170
  V. 4. 5 Wire drawing 
171
  V. 4. 6. Swaging 
172
  V. 4. 7 Spinning
173
  V. 4. 8 Sheet metal drawing (deep drawing)
174
  V. 4. 9 Shearing   
175
  V. 4. 9. 1 Straight shearing
175
  V. 4. 9. 2 Die-shearing
175
V. 5. Non-conventional metal forming processes
176
 
 
CHAPTER VI – WELDING
183 – 212   
VI. 1. Introduction
183
VI. 2 Pressure welding
183
  VI. 2. 1 Forge welding
183
  VI. 2. 2 Electric resistance welding   
185
  VI. 2. 2. 1 Spot welding 
186
  VI. 2. 2. 2 Seam welding 
187
  VI. 2. 2. 3 Butt welding 
188
   VI. 2. 2. 3. 1 Upset butt welding 
188
  VI. 2. 2. 3. 2 Flash butt welding 
189
  VI. 2. 2. 4 Projection welding 
189
   VI. 2. 2. 5 Percussion welding 
190
VI. 3 Non-pressure welding (fusion welding)
191
VI. 3. 1 Gas welding 
190
  VI. 3. 1. 1 Oxy-acetylene welding 
191
   VI. 3. 1. 1. 1 Gas flame 
193
  VI. 3. 1. 1. 2 Gas welding technique 
194
  VI. 3. 1. 1. 3 Gas welding equipment
196
  VI. 3. 1. 2 Other types of gas welding 
200
  VI. 3. 1. 2. 1 Oxy-hydrogen welding 
200
  VI. 3. 1. 2. 2 Air-acetylene welding 
200
  VI. 3. 1. 3 Advantages and limitations
200
  VI. 3. 2 Arc welding 
201
 
Page No
   VI. 3. 2. 1 Arc welding equipment 
202
  VI. 3. 2. 1. 1 A.C and D.C machines
202
  VI. 3. 2. 1. 2 Arc welding electrode 
203
   VI. 3. 2. 2 Arc welding methods 
205
  VI. 3. 2. 2. 1 Carbon arc welding 
205
  VI. 3. 2. 2. 2 Metal arc welding 
206
  VI. 3. 2. 2. 3 Metal inert-gas welding 
207
  VI. 3. 2. 2. 4 Tungsten inert-gas welding 
208
   VI. 3. 2. 2. 5 Submerged arc welding
209
BIBLIOGRAPHY 
211 - 213