Iff
 i
title
author
publisher
in bulk
any part may
classification of
presentation
of
chapters having
wishing
analytical.
The enhancements included
authority
This editionincludesenhancements
chapters
in
completely
most
important casting processes
have been added.
important plastic processes
have been added.
efficient
practicing
designers
and
manufacturing
mainly
every year
Siggaard
has
industry
systematic engineering approach
systematic process development, systematic
A
encouraged
In order to
application
of
safety.
A
version of this material has been usedas a textbook at The Technical
University
about 42 class
Along
textbook for a fundamental
suggested improvements
Dr. G.
Preface to the First Edition
vii
Properties
3.4
Instability
4.4
Tf
processes
are
based
is
introduced
By
defining
and
considering
Fig.
1.1.
types,
shape
material and the
tool or die.
+
model,
a
knowledge
of
state,
and
granular
by
their
The basic
processes,
The
various
single
basic
processes
are
Categories
of
BasicProcesses
Mechanical
Examples
of
processes
types.
conserving,
solid
a
suitable
H\\gjj/TJ
N/
at
h.
The
strength
of
the
components
after
sintering
can,
depending
on
cutting
tool
 see
Fig.
1.8a .
By varying
the tool
coolant,
maintains
a
has
a
characteristic
the
anode,
supplied
continuously.
A
torch
is
designed
to
provide
heat
both
for
starting
and
maintaining
the
processes.
1.5
can,
depending
the field
that
the
necessary
mechanical
energy
can
be
generated:
As
mass
forces
directly
energy
source
must
be
material,
attracting
or
repelling
^wwww^
 
supply,
in
heat
through
which
passes
a
placed
between
the
plates
of
a
capacitor,
and
hence
subjected
to
an
alternating
two
electrodes
K
Spa
ments to
requirements
for
the
they
require
emphasized
that
the
media
  0,
and
02)
can,
at
geometry,
which
along
the
line
of
geometry,
which
the
media
may
degenerate
to
a
according
elements. Thismethod
ODF
Continuous
casting
Rolling-casting
 b)
cutting
and
the
feeding
motions.
are
small,
the
pattern
the
work
material,
since
a
fluid
medium
 with
solid
particles ,
necessary
to
chapter
considered
since
they
are
important
to
both
the
design
testing
conditions.
With
caution
and
employing
a
\302\256
load
and
elongation
Fig.
2.4.
In
by
necking
takes
place
in
true stress
Fig.
for
increasing
strain
rate,
an
increasing
stress
is
required.
Many
of the
its
in
millimeters.
The
hardness
number
is
always
quoted
without
units,
although
in
reality
it
has
the
previous
system
of
units,
are in
used,
Brinell test can be
satisfactorily only
The
applied
load
in
a
diamond
cone
is
usually
used
identified
by
resistance
to
elastic
temperature,
brittle behavior
low
temperatures
under
loadings,
to
that a
be
processed
by
a
given
process
or
process
group.
To
following phases
produced,
the
next
question
is
the
availability
from the
tearsoccur
constituents,
is
generally
produced
by
a
large
continuous research
range
of
applicable
materials.
3.2.2
Forming
from
the
Solid
by
mass-conserving
processes,
mass-reducing
processes,
or
joining
processes.
Mass-Conserving
Processes
In
the
forming
of
metals,
the
primary
basic
process
is
mechanical
plastic
deformation
 see
Chapter
1).
The
suitability
strain curves
important,
as
they
the material
canbe machined.
in
poor
surfaces.
from
the
machining
zone.
These
processes
are
largely
influenced
by
3.3
EFFECT
OF
influences
the
surface
defects
and
thus
the
properties.
state,
that
is,
hardening
from:
a.
Martensitic
 diffusionless
ransformations
b.
Precipitation
and
solution
 diffusion
2.
Strain
hardening
3.
Dispersion
hardening
 see
Section
3.11.1
Hardeningy
body-centered
cubic
structure
(of
ferrites)
becomes
supersaturated
with
carbon
atoms;
martensitic hardness is about
figures
are
HV
increased. If
solution treatment
Aging
 or
precipitation)
at
room
temperature
takes
about
4
days,
but
the
carbonitriding
process,
it is
emphasized
that,
matrix
is
iron
(Fe,
the
parent
metal)
having
varying
very
than 5
steels.
3.
High-alloy
steels
high-temperature
steels.
standards
(ANSI,
Heat-resistant
steels
the
standards
must
be
studied.
The
preceding
examples
carefully, giving
of
W,
Cr,
V,
and
Ni.
Application
examples:
forging
dies,
casting
dies,
extrusion
dies.
of
W,
Cr,
matrix
Co
is
generally
used,
but
nodular or
type
railroad,
automobile,
pipe-fitting,
and
agricultural
industries.
attractive.
 
 at
room
temperature
and
at
increased/elevated
temperatures,
they
drops
rapidly
with
increasing
temperatures,
but
they
use
of
carbides
in
cutting
tools.
and
mentioning
prior
warning
relatively
high,
engineering
materials.
Machining
is
problematic,
so
products
must
be
fabricated
hrough
the
use
bricks. Another
being developed
for use
vary
improve strength
compression
 tensile
strengths
in
excess
of
3.5
kN/mm2
and
resistance
to
high
temperatures
 up
to
woven into
can be
wing
and
is
an
important
factor
in
describe
plastic
every
acting
direction of the
stresses do
system
x,
y-system).
change
in
sign
occurs
when
the
principal
planes.
The
magnitude
of
principal planes,
^=
strain
does
not
M
-\ \ M
^<\302\243-\342\200\224\342\200\242\342\200\224v
twe>
/
*
compression
and
in
tension,
or
 1
original
state.
0 1
instability.
_
_
[Eq.
 4.24 ]
o,
e-instability
condition,
giving
the
o,
e-instability
condition
yield
a
critical
value.
correct
15 .
By
introducing
a
factor
be reduced.
yielding
differs
as
mentioned
yielding
ductile metals it has
nd
=
provided
in
the
1-direction
(rolling
and
plane
strain
compression,
for
curve,
giving,
for
example,
the
by
i
 o,
e
obtained
from
a
tensile
for Different
Complex Systems
CO
f\342\200\224
\\\342\200\224\\-\\\342\200\2241\342\200\224I\342\200\2241
v-J.\342\200\224V,\342\200\2241
Homogeneous
Friction
h
 a)
 b)
that
this
only
D2
and
 
based
directly
on
the
morphological
materials,
but
only
major
determined
by
the
type
material
and
cold
working
The
following:
translations
 T ,
rotations
 R ,
 
i
\342\226\240:\342\200\242\342\200\242\342\200\242\342\200\242:
^^h
Examples
of
processes
Forging
Bending
Impact
forging
or
most
of
the
desired
surface
 i.e.,
the
I v^-^^^i
V \\zc
of
the
component,
thus
requiring
a
(see
Fig.
6.2).
The
principles
zone
cylindrical
when the
major
factors
affecting
knowledge
considered
only
Stateof deformation:
low-alloy
and
0.005,
extensively
common. The
energies
necessary
are
discussed.
available,
but
piece.
For
example,
the
 6.4)
where
e
refers
=
Sincethe extrusion
<615>
where
in
wire
drawing,
directly
pass
blank,
+
general
background,
allowing
a
primary
evaluation
been directed toward
workpiece,
properties
of
the
energy
source
and
the
pattern
of
motions .
or the
5Per
ed9e
FIGURE
vf/n
Feed
 per
tooth
nun/tooth
f2
workpiece.
In
turning,
length
of
work-
piece.
In
be
expressed
by
will
possess
the
f
Cutting
i
process
plane
AB,
but
in
models have been
actual shear
chip
is
similar
detail,
but
steels of about
0.5-2.0 C when
(increased
tool
life)
Cooling
epending
on
the
type
of
quality
workpiece
and
to
provide
good
surface
quality,
larger
are
applicable,
the
range
piece. Increasing
on
tool
geometry,
see
the
literature
[16-18]
in
time
is
very
important
since
it
time until
feed,
radius,
the
major
cutting-edgeangle,
choice of
i
 5
cutting
CI
13)
Q
This
the
required
functional
properties;
its
technological
properties
describing
the
suitability
of
the
material
materials,
material
groups.
The
machinability
is
again
lay
is
the
direction
of
the
predominant
surface
Turning:
 a)
the corner radius r of the too and the feed determine
the
surface
roughness;
 b)
so
principle
 TF,
ODF,
TDF,
FF ,
the
pattern
of
motions
for
must be
established. It
must be
types
of
motions
available
are:
Translations
Rotations
Stationary
Considering
the
primary
table
desired surface
possess
positioning
or
adjustment
variety
of
shapes
restricted
or to the
Figure
machine,
but
because
of
the
spindle
construction,
spindle,
permitting
a
quick
tool
change,
boring, drilling,
become
extremely
important
in
recent
years,
because
of
the
increasing
demands
of
high
accuracy
and
quality.
Formerly,
grinding
was
used
only
for
as
in
beyond
the
scope
axial cross-sectional
shapes  including
 HB
the various
Finer
tolerances
may
be
obtained,
but
finishing
is
in the
=
type
=
to 0.8.
It should
units
traditionally
used
in
the
machining
field.
The
radial
force
Pr
has
Shaping
and
Planing
As
in
turning,
three
Drilling
In
drilling
with
twist
drill,
two
of the
join
elements
or
componentsare
described.
metallic
crystals,
is
established
through
basic
the
thread,
spring
elements,
requirements
must
joined.
The
bonding
conditions
are
fulfilled
through
cleaning
 mechanical
such
as
wirebrushing
and/or
chemical
and
proper
design
characteristics in
maximum and minimum.
The
electron
The total arc
length.
roughness
of
the
parts,
short-circuiting
does
not
an order
ways.
First,
it
a lower
the work
material and
good
mechanical
properties.
This
coating,
in
general,
The
arc
gas
Filler
material
(TlG-welding)
(e)
(f)
is
the
cheapest
gas.
the
workpieces
with
a
high-intensity
In
welding,
the
power
is
mostly
flames,
or
joining
is
known
as
Thermit
welding.
Gas
Welding
eached
-
material
being
welded.When
layers
pool
required
with
copper
with water
from the
the Thermit and the ultimate
analysis
s,
a
superheat
of
Type
of
energy
for
heating
Type
of
energy
to
create
pressure
Process
groups
(examples)
Electrical
Mechanical
Chemical
Mechanical
Mechanical
Mechanical
Mechanical
Chemical*
Mechanical\
Cold
welding
Resistance
welding
Friction
welding
Pressure
electrodes must be
welding
of
be
rotating
disks
 see
Fig.
8.13b .
of
the
clamping
tools,
which
supplies
the
necessary
clamping
or
welding
force
 brazing
and
soldering)
and
non-
joined
by
these
processes.
Because
used
for
soldering
or
brazing
extensively
in
brazing
 see
Table
8.3
8.4
shows
typical
groups
of
brazing
on the basis
activates the
in
Section
the
same
composition
and
to 5
through
the
resistance
spot
welding
process.
suitable characteristics.
joined
to
heavy
to the state
grains
or
particles
possibly
of
varying
following
reasons:
The
production
of
simple
or
sealed
drums
together
with
coal
vary,
and
the
general
S^
>i
4J
N/mm2,
which
4
\342\226\240\342\226\240\342\226\240:\342\226\240\342\226\240\342\226\240\342\226\240\342\226\240-4
111
am.*
f
it
^^3
of
double-action
compaction
is
obtained
by
the
floating
container,
which
moves
a
[30].
Various
Compacting
or
Shaping
Methods
phase
Iron
powders
are
normally
sintered
in
the
range
strength
has
the
desired
density.
This
temperature.
The
materials
are
generally
a
in
heavy
applications,
but
procedure
2
has
quite
a
few
applications.
propertiesequal
to
the
corresponding
solid
material,
with
even
better
fatigue
properties.
Concerning
dimensional
accuracy,
it
can
generally
be
stated
that:
Pressing
avoided
Sharp
edges,
corners,
powder
compaction
isostatic
compaction
of
special
components.
industry,
etc. .
Having
a
good
knowledge
the work and the
short
introduction
to
the
primary
characteristics
furnace ,
a
refining
process
or
correction
of
the
composition
a
refining
process
increases.
complicated
shapes,
filled,
causing
phosphor
content
often
Frequently
thermal
basic
process
is
production
rate
is
typically
8-10
Liquid
Materials:
Casting
Processes
309
Charging
\ \ \ \302\273\302\273\302\273\302\273\302\273\302\273\302\273\342\226\240\302\273\302\273\302\273\302\273\342\226\240\302\273'
7
Lining
Shell
Wind
box
Tuyeres
Preheating
zone
Melting
zone
Superheating
zone
Crucible
Taphole
Mw;/;//////yZ>////,
^^ Lm
w//////////////////a
FIGURE
10.2
Furnaces
using
energy:
(A)
cupola;
(B)
open-hearth
furnace
(a,
commonly
in
the
production
that the final
requirements
permanent
and
marks where the two halves
of
component
either in the
pattern necessary
piece
 like
the
desired
component
with
allowances
or
split
along
a
plane
or
irregular
surface
to
Hk
RF
(b)
is
compensated
for
by
the
application
casting
attached
or
completely
filled
may
close
to
prevent
further
feeding
to
maintained.
The
fundamental
requirements
of
the
molding
principle
is
generally
total
forming.
The
tool,
determining
the
shape
of
the
cavity,
is
called
a
pattern
and
was
described
in
with a
The dies for die
graphite
or
induction
furnace,
replaced
by
a
metal
mold,
d to create
components depends directly
can be
cast
iron,
depending
on
castings
are
described
briefly
below.
Figures
10.15
*2
 c
FIGURE
10.15
rules
for
castings:
 a
changing
of
dimensions;
 b
changing
of
directions;
 c
T-joints.
excess
metal
to
compensate
for
shrinkage
during
solidification
of
the
casting.
casting.
Applications:
Sand
casting
of
cast
flaskswith handles and
from
the
mold.
Workpieces
with
wall
thicknesses
as
thin
as
parting
transferred
to
components
of
a
wide
range
of
the manufacturers
must be
that
most
thermoplastic
partially
cured
state.
If
forming
is
carried
heating
and
and then
water cooled. The
developed.
The
molding
machines
properties
closedunder the
drawn onto
mold
is
wood, metal,
plastic
shape.
only
with
great
difficulty
or
sometimes
not
at
all.
and
so
magnetic
fields
explosives
large
potential
in
developing
new
principles
of
materials
processing.
12.2
PROCESSES
The
nontraditional
processes
will
be
grouped
/
both
electrode and
two
workpiece.
An
erosion
of
the
workpiece,
and
ability
of
surface
uniformity
reduces
the
time
necessary
graphite
workpiece
during
the
of
lubricants.
by spark discharges.
the
wheel
speed
of
light.
This
high-speed
impingement
of
high-velocity
electrons
Process
Capabilities
and
Applications
not
is
approximately
0.2-0.5
mg/s.
However
EBM
makes
possible
the
production
of
Fig.
12.11,
three
types
of
joints
are
unique
to
once,
one
guide
hard martensite.
Because the
state,
two
quanta
of
energy
or
photons
are
radiated,
and
the
electron
drops
powerful
enough
to
ensure
to
molecules
other
solid-state
lasers,
which
operate
only
illuminated
workpiece
material
to
both
partially
melt
and
as a
They
the
of
and
blowing
away
poor
kerf
quality.
typically
thicknessbelow
the
surface,
using
very
high
melting
points.
work-
piece,
rapidly
heated
beyond
its
upper
critical
temperature
transforming
it
shield
gas
rolls
Mechanical
Engineering
Automotive
industry
Springs
Gear
parts
expanding gas
commonly
used
for
cleaning,
cutting,
and
deburring,
while
polishing
or
peening
important.
Best
cut-
;
.197\ . ..025\ .
is
low,
usually
about
50-100
mg/min,
a
ductile
material
of
the
vibration
amplitude
and
to
necessary
surface
finish.
Coarse
grits
promote
efficient
jim
RMS
 800-grit .
For
accurate
holes,
rough
and
finish
tistep
production
of
siliconnitride
 Si3N4
turbine
blades.
machining,
in
contrast
metal is
and
motors
must
be
protected
by
sealing
and
may
even
same
possibilities
to drill holes of a diameter of 1 mm to
depths
spacing
of
the
holes,
this
part
was
previously
made
by
drilling
the
holes,
one
at
round holes. Since the
commonly
used
members
of
the
family
excess
material.
Today
a
new
group
of
functional
parts
in
larger
assemblies,
but
bearing
processes
basedon
the
principle
of
material
increase
is
to
based
on
polymerization.
It
was
the
first
the
part
is
solidified.
The
whole
cycle
is
repeated
contour
of
drops
so
that
after
collision,
fusing,
and
curing,
they
are
^
00
00
00
\342\226\240\342\226\240\342\226\240\342\226\240\342\226\240\342\226\240\342\226\240\342\226\240\342\226\240\342\226\240
FUNCTIONAL
LAYOUT
d-d
o
1 O
oaocdb
PRODUCT
LAYOUT
FIGURE
applied
for
classifying
parts
into
part
families
are
usually
similarities
of
shape,
materials,
and
types
grouped
together
materials;
in
essence,
job shop.
2. GT
To
comprehensive
parts
the
be
programmed
to
operate
according
to
a
cyclic
schedule,
using
CAD/CAM
systems.
CAD
(computer
aided
design)
ystems
are
computer-based
wm. 0-an
*  a**\ vi
FIGURE 13.5
Typical machining
problem coping
with the
itself
manipulators,
 a)
The
articulated
manipulator,
 b)
The
Cartesian
manipulator.
by
servo-drivers.
These
motion.
Figure
Most
industrial
possible,
the
are
and
cavities
to
directly say
that the
for
being
Company.
But
developments
in
computer
and
system.
The
use
production.
normally
lifting
capacity
and
feeding
machine
tools,
shop
machine tool manufacturers. These
concept,
enabling
the
system
to
be
configured
\ Fanuc
two-floor
building.
.*&
302\273
\342\226\240
.
'
,\\
'
CIM
concept
[63].
management
systems.
A
major
programmed
manually.
The
computer-aided process planning
to
value
of
input
The
definition
of
productivity
can
be
applied
developed
further
many
places
still
educated and
similarly
in stock
the
principle
often
applied
in
JIT
the
manufacturing
components
have
the success we
opposition
to
all
represent
lived
up
of
employees
have
especially
been
neglected
or
underestimated.
It
on the
manufacturing
processes
waste
violated.
polluted
waste
clean\342\200\224do not mix chemical wastes since this
prevents
later
reworking
of
become
a
part
of
company
policy
as
customers,
agencies,
and
authorities
system may
regulations
New
Method],
technology,
Welding
Journal,
July
1980,
pp.
51-57.
Just-In-Time
Manufacturing,
IFS
Publications,
1988.
Networking.
McGraw-Hill,
New
York,
1988.
law valid?
force
stresses
t)
 see
Fig.
P4.4)
is
subjected
natural
 true)
strains
in
by
the
analytical
expression
a
to be
Pm>x
pass.
in
a
characteristics of
frequently
used
types
of
furnaces
for
melting?
Give
o
o
o
<7v
\302\260V
Cfi
=
0.17
6.11
P