Metal Shaping Processes

As the only comprehensive text focusing on metal shaping processes, which are still the most widely used processes in the manufacture of products and structures, Metal Shaping Processes carefully presents the fundamentals of metal shaping processes with their relevant applications. The treatment of...

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Bibliographic Details
Main Author Boljanovic, Vukota
Format eBook
LanguageEnglish
Published La Vergne Industrial Press, Incorporated 2009
Industrial Press, Inc
Industrial Press
Edition1
Subjects
Metal work
Online AccessGet full text
ISBN0831133805
9780831133801

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Table of Contents:
  • 4.2.2 Particle Shape and Internal Structure -- 4.2.3 Friction and Flow Characteristics of Particles -- 4.2.4 Packing, Density, and Porosity -- 4.3 Production of Metallic Powder -- 4.3.1 Atomization -- 4.3.2 Mechanical Processes -- 4.3.3 Chemical Processes -- 4.3.4 Electrolytic Deposition -- 4.3.5 Hybrid Atomization -- 4.4 Powder Manufacturing Processes of Metal Parts -- 4.4.1 Blending and Mixing of the Powders -- 4.4.2 Compaction of Metallic Powder -- 4.4.3 Sintering -- 4.4.4 Secondary Operations -- 4.4.5 Isostatic Pressing -- 4.4.6 Powder Injection Molding -- 4.4.7 Powder Rolling, Extrusion, and Forging -- 4.4.8 Liquid Phase Sintering -- 4.5 Powder Metallurgy Materials -- 4.5.1 Conventional Materials -- 4.5.2 Advanced Materials -- 4.6 Design Considerations in Powder Metallurgy -- 4.6.1 Tooling Considerations -- 4.7 Economics of Powder Metallurgy -- PART III DEFORMATION PROCESSES -- Chapter 5 Fundamentals of Metal Forming -- 5.1 Introduction -- 5.2 Classification of Metal Forming Processes -- 5.3 Material Behavior in Metal Forming Processes -- 5.3.1 Tensile Properties -- 5.3.2 Flow Stress -- 5.4 Temperature in Metal Forming -- 5.4.1 Cold Working -- 5.4.2 Warm-Working -- 5.4.3 Hot Working -- 5.4.4 Isothermal Forming -- 5.5 Effect of Strain Rate -- 5.6 Friction in Metal Forming -- 5.7 Lubrication in Metal Forming -- Chapter 6 Rolling of Metals -- 6.1 Introduction -- 6.2 Flat Rolling Process -- 6.2.1 Analysis of Workpiece Deformation by Flat Rolling -- 6.2.2 Roll Force, Torque, and Power -- 6.2.3 Vibration and Chatter -- 6.3 Shape Rolling -- 6.4 Tube Rolling Process -- 6.4.1 Pierce and Pilger Rolling Process -- 6.4.2 Plug Rolling Process -- 6.4.3 Continuous Mandrel Rolling Process -- 6.4.4 Push Bench Process -- 6.5 Ring Rolling -- 6.6 Rolling Mills -- Chapter 7 Forging -- 7.1 Introduction -- 7.2 Hand Forging -- 7.2.1 Tools and Equipment for Hand Forging
  • 7.2.2 Fundamental Hand Forging Operations -- 7.3 Open Die Forging -- 7.3.1 Analysis of Open Die Forging -- 7.4 Impression Die Forging -- 7.4.1 Analysis of Impression Die Forging and Flash Land Geometry -- 7.5 Flashless Die Forging -- 7.6 Various Forging Processes -- 7.6.1 Coining -- 7.6.2 Heading -- 7.6.3 Hobbing -- 7.6.4 Orbital Forging -- 7.6.5 Isothermal Forging -- 7.6.6 Swaging and Radial Forging -- 7.7 Forgeability of Metals -- 7.8 Forging Die Design and Die Materials -- 7.8.1 Customer Technical Specification -- 7.8.2 Die Design -- 7.8.3 Testing of the Die -- 7.8.4 Customer Approval -- 7.8.5 Die Wear and Die Materials -- 7.9 Forging Machines -- 7.9.1 Forging Presses -- 7.9.2 Forging Hammers -- Chapter 8 Extrusion and Drawing of Metals -- 8.1 Extrusion -- 8.1.1 Direct Extrusion -- 8.1.2 Indirect Extrusion -- 8.1.3 Hydrostatic Extrusion -- 8.1.4 Impact Extrusion -- 8.1.5 Hot Versus Cold Extrusion -- 8.1.6 Analysis of Extrusion -- 8.1.7 Defects in Extrusion -- 8.1.8 Extrusion Dies and Presses -- 8.2 Drawing -- 8.2.1 Wire and Bar Drawing -- 8.2.2 Tube Drawing -- 8.2.3 Mechanics of Drawing -- Chapter 9 Sheet Metal Working -- 9.1 Introduction -- 9.2 Cutting Processes -- 9.2.1 Shearing -- 9.2.2 Cutoff and Parting -- 9.2.3 Blanking and Punching -- 9.2.4 Other Sheet Metal Cutting Operations -- 9.3 Bending Processes -- 9.3.1 Mechanics of Bending -- 9.3.2 Bend Allowance -- 9.3.3 Bend Radius -- 9.3.4 Bending Force -- 9.3.5 Springback -- 9.3.6 Three-Roll Bending -- 9.3.7 Other Bending and Related Forming Operations -- 9.4 Tube and Pipe Bending -- 9.4.1 Press Bending -- 9.4.2 Rotary Draw Bending -- 9.4.3 Compression Bending -- 9.4.4 Roll Bending -- 9.5 Deep Drawing Process -- 9.5.1 Mechanics of Deep Drawing -- 9.5.2 Deep Drawability -- 9.5.3 Blank Size Determination -- 9.5.4 Blank Reduction Percentage -- 9.5.5 Drawing and Ironing Force
  • Metal Shaping Processes -- Front Matter -- Title Page -- Copyright -- Dedication -- Table of Contents -- Preface -- Introduction -- General Processes Overview -- Classification of Shaping Processes -- Production Equipment and Tooling -- PART I CASTING AND MOLDING -- Chapter 1 Fundamentals of Metal Casting -- 1.1 Introduction -- 1.2 Heating the Metal -- 1.3 Pouring the Molten Metal -- 1.3.1 Engineering Analysis -- 1.4 Fluidity -- 1.4.1 Test for Fluidity -- 1.5 Solidification and Cooling of Metals -- 1.5.1 Solidification Time -- 1.5.2 Shrinkage -- 1.6 Defects in Casting -- Chapter 2 Metal Casting Processes -- 2.1 Introduction -- 2.2 Sand Casting -- 2.2.1 Foundry Sands -- 2.2.2 Patterns -- 2.2.3 Cores -- 2.2.4 Types of Sand Molds -- 2.2.5 Sand Molding Techniques -- 2.2.6 The Sand Casting Operation -- 2.2.7 Rammed Graphite Molding -- 2.3 Other Expendable Mold Casting Processes -- 2.3.1 Shell Molding -- 2.3.2 V-Process -- 2.3.3 Evaporative Pattern Casting Process -- 2.3.4 Investment Casting -- 2.3.5 Plaster Mold Casting -- 2.3.6 Ceramic Mold Casting -- 2.4 Permanent Mold Casting Processes -- 2.4.1 Basic Permanent Mold Casting -- 2.4.2 Vacuum Permanent Mold Casting -- 2.4.3 Slush Casting -- 2.4.4 Pressure Casting -- 2.4.5 Die Casting -- 2.4.6 Centrifugal Casting -- 2.4.7 Squeeze Casting -- 2.5 Melting Practice and Furnaces -- 2.5.1 Furnaces -- Chapter 3 Metal Casting: Design and Materials -- 3.1 Introduction -- 3.2 Casting Design Considerations -- 3.2.1 General Design Considerations for Casting -- 3.3 Computer Modeling of Casting Processes -- 3.4 Metals for Casting -- 3.4.1 Cast Irons -- 3.4.2 Cast Steels -- 3.4.3 Nonferrous Casting Alloys -- PART II PARTICULATE PROCESSING FOR METALS -- Chapter 4 Powder Metallurgy -- 4.1 Introduction -- 4.2 Characteristics of Metal Powders -- 4.2.1 Particle Size Measurement and Distribution
  • 9.5.6 Blankholder Force -- 9.5.7 Deep Drawing Practice -- 9.5.8 Clearance -- 9.5.9 Drawing Defects -- 9.6 Other Sheet Metal Forming Processes -- 9.6.1 Stretch Forming -- 9.6.2 Spinning -- 9.6.3 Rubber Pad Forming -- 9.6.4 Hydroforming Process -- 9.6.5 Superplastic Forming and Diffusion Bonding -- 9.7 Classification and Types of Dies -- 9.7.1 Die Classification -- 9.7.2 Types of Dies -- 9.8 Presses for Sheet Metal Working -- 9.8.1 Mechanical Presses -- 9.8.2 Hydraulic Presses -- 9.9 High-Energy Rate Metal Forming Processes -- 9.9.1 Explosive Forming -- 9.9.2 Electrohydraulic Forming -- 9.9.3 Electromagnetic Forming -- PART IV METAL REMOVAL PROCESSES -- Chapter 10 Fundamentals of Metal Machining -- 10.1 Introduction -- 10.2 Mechanics of Machining -- 10.2.1 Types of Cutting -- 10.2.2 Chip Formation -- 10.3 Cutting Force and Power -- 10.3.1 Cutting Force -- 10.3.2 Power -- 10.4 Thermodynamics of Cutting -- 10.4.1 Cutting Heat -- 10.4.2 Cutting Temperature -- 10.5 Tool Wear and Tool Life -- 10.5.1 Tool Wear -- 10.5.2 Taylor's Tool Life Theory -- 10.6 Cutting Fluids -- 10.6.1 Methods of Cutting Fluid Application -- 10.6.2 Types of Cutting Fluids -- 10.7 Surface Finish -- 10.7.1 ISO Surface Finish -- 10.8 Cutting Tool Materials -- 10.8.1 Tool Steels and Cast Alloys -- 10.8.2 Carbides -- 10.9 Machinability -- 10.9.1 Effects of Chemical Composition and Physical Characteristics of Materials -- 10.10 Selection of Cutting Conditions and Machining Economics -- 10.10.1 Selecting Cutting Conditions -- 10.10.2 Machining Economics -- Chapter 11 Machining Processes -- 11.1 Introduction -- 11.2 Turning -- 11.2.1 Machining Operations Related to Turning -- 11.2.2 Cutting Conditions in Turning -- 11.2.3 Cutting Tools for Turning Operations -- 11.2.4 Lathes -- 11.2.5 Boring -- 11.3 Drilling -- 11.3.1 Types of Drills -- 11.3.2 Cutting Conditions in Drilling
  • 11.3.3 Reaming -- 11.3.4 Machines for Drilling -- 11.4 Milling -- 11.4.1 Types of Milling Operations -- 11.4.2 Generation of Surfaces in Milling -- 11.4.3 Cutting Conditions in Milling -- 11.4.4 Milling Cutters -- 11.4.5 Milling Machines -- 11.5 Sawing -- 11.5.1 Types of Sawing -- 11.5.2 Saw Blades -- 11.6 Planing and Shaping -- 11.6.1 Planing and Planers -- 11.6.2 Shaping and Shapers -- 11.6.3 Cutting Conditions -- 11.7 Broaching -- 11.7.1 Broaches -- 11.7.2 Broaching Machines -- 11.8 Gear Manufacturing -- 11.8.1 Gear Terminology and Definitions -- 11.8.2 Methods of Manufacturing Gears -- 11.8.3 Gear Finishing Processes -- Chapter 12 Abrasive Machining Processes -- 12.1 Introduction -- 12.2 Abrasives -- 12.2.1 Abrasive Grain Size and Geometry -- 12.3 Grinding -- 12.3.1 Grinding Wheels -- 12.3.2 Analysis of the Grinding Process -- 12.3.3 Grinding Operations and Machines -- 12.4 Finishing Operations -- 12.4.1 Honing -- 12.4.2 Lapping -- 12.4.3 Superfinishing -- 12.4.4 Polishing and Buffing -- Chapter 13 Nontraditional Machining Processes -- 13.1 Introduction -- 13.2 Mechanical Energy Processes -- 13.2.1 Ultrasonic Machining -- 13.2.2 Water-Jet Cutting -- 13.3 Electrochemical Machining Processes -- 13.3.1 Electrochemical Machining -- 13.3.2 Electrochemical Grinding -- 13.4 Thermal Energy Processes -- 13.4.1 Electric Discharge Processes -- 13.4.2 Laser Beam Machining -- 13.4.3 Electron Beam Machining -- 13.5 Chemical Machining -- 13.5.1 Chemical Milling -- Index