Академический Документы
Профессиональный Документы
Культура Документы
Chapter 1 (Callister)
Study outcomes:
•Appreciate the development and increase in diversity of
materials.
•Know and define material properties
•Know the five family of materials
•Understand the classification system for a material .
•Know the three families of processing of a material
•Understand the classification system of the process.
•Process property interaction
•Specify a material and /or process for manufacturing of a
given component
1.1 Materials , process and choice.
The first row contains primary shaping process below it secondary process, followed by family of joining and finishing
• Primary process creates shapes. The six primary
process are listed :like casting , molding, deformation
methods , powder methods, methods for forming
composites, special methods.
• Secondary process: modifies the shapes and properties.
Like machining which add features to already shaped
body, heat treatment which enhances surface or bulk
properties.
• After secondary process comes joining and surface
treatment
• Sand casting : it consists of following steps
• Placing a pattern having the shape of
desired casting in sand to make an imprint
• Incorporating the gating system
• Filling the resulting cavity with molten
metal
• Allowing the metal to cool until it solidifies
• Breaking away the sand mold
• Removing the casting
• Investment casting / lost wax process:
• The pattern is made of wax by injecting wax into
a metal die in the shape of pattern
• The pattern is dipped in slurry of refractory
material. After initial coating has dried, the
pattern is coated repeatedly to increase the
thickness
• Then the mold is dried in air and heated to
remove wax by keeping in inverted position
• Nos of molds are made and joined to form a tree
to increase the production rate.
• Then molten metal is poured into these molds
which take the shape, and once solidified they
are taken out
• Die casting/ permanent mold casting: in
this two halves of the mold is made of
materials such as cast iron steel or
refractory metals
• The molds are clamped together by
mechanical means
• Deformation methods : ex rolling , forging,
drawing, extrusion
• Rolling :It is process of reducing thickness
or changing cross- section of long work
piece by compressive force applied
through a set of rolls
• Main products are flat plate, sheet and foil
in long length, production of seamless
tubing's.
• Rolling may be carried out at room
temperature (cold rolling) or at elevated
temperature (hot rolling)
• Forging is the process by which metal is heated
and is shaped by plastic deformation by suitably
applying compressive force. Usually the
compressive force is in the form of hammer
blows using a power hammer or a press.
• Forging refines the grain structure and improves
physical properties of the metal. With proper
design, the grain flow can be oriented in the
direction of principal stresses encountered in
actual use. Grain flow is the direction of the
pattern that the crystals take during plastic
deformation. Physical properties (such as
strength, ductility and toughness) are much
better in a forging than in the base metal, which
has, crystals randomly oriented.
• Extrusion : It is a process of forcing a billet
through a die, in a manner similar to
squeezing toothpaste from a tube. Almost
any solid or hollow cross section may be
produced by extrusion.
• Typical products made by extrusion are
railings for sliding doors, tubings having
various cross sections.
• Drawing is an operation in which the cross
section of solid rod , wire or tubing is
reduced or changed in shape by pulling it
through a die
• Products are wire and wire cables
Welding electrodes, springs , paper clips,
spokes for bicycles, stringed musical
instruments etc.
• Deep drawing . Basically a sheet forming
process. Main products are beverage
cans, kitchen sinks, automotive fuel tanks
etc.
• Molding methods ( mainly for shaping
plastics)
• Injection molding: in this process the
granules or pellets are fed from the hopper
to the rotating screw system or hydraulic
plunger. The granules / pellets are heated
and are forced into a split die chamber.
• Typical products include cups , containers,
electrical and communication components,
toys etc.
• Blow molding: it is modified form extrusion
and injection molding process together .
The blow molding process begins with
melting down the plastic and forming it into
a preform. The preform is a tube-like piece
of plastic with a hole in one end in which
compressed air can pass through. The
parison is then clamped into a mold and
air is pumped into it. the air pressure then
pushes the plastic out to match the mold.
Once the plastic has cooled and hardened
the mold opens up and the part is ejected
• Powder metallurgy uses sintering process for
making various parts out of metal powder. The
metal powder is compacted by placing in a
closed metal cavity (the die) under pressure.
This compacted material is placed in an oven
and sintered in a controlled atmosphere at high
temperatures and the metal powders coalesce
and form a solid. A second pressing operation,
repressing, can be done prior to sintering to
improve the compaction and the material
properties.
in a broad manner the process universe can be
classified as three families : shaping , joining and surface
treatment.