This Page Intentionally Left Blank Principles of Metal Manufacturing Processes J. Beddoes & M. J. Bibby Carleton University, Canada ELSEVIER BU'ITERWORTH HEINEMANN AMSTERDAM 9 BOSTON ~ HEIDELBERG ~ LONDON ~ PARIS 9 SAN D I E G O 9 SAN FRANCISCO~ SINGAPORE NEW YORK o-OXFORD 9 SYDNEY 9 TOKYO Elsevier ButtenNorth-Heinemann Linacre House, Jordan Hill, Oxford OX2 8DP 200 Wheelers Road, Burlington, MA 01803 First published 1999 Reprinted 2003 Copyright 9 2003, J. Beddoes and M. J. Bibby. All rights reserved The fight of J. Beddoes and M. J. Bibby to be identified as the authors of this work has been asserted in accordance with the Copyright, Designs and Patents ACt 1988 No part of this publication may be reproduced in any material form (including photocopying or storing in any medium by electronic means and whether or not transiently or incidentally to some other use of this publication) without the written permission of the copyright holder except in accordance with the provisions of the Copyright, Designs and Patents Act 1988 or under the terms of a licence issued by the Copyright Licensing Agency Ltd, 90 Tottenham Court Road, London, England WlT 4LP. Applications for the copyright holder's written permission to reproduce any part of this publication should be addressed to the publisher Permissions may be sought directly from Elsevier's Science & Technology Rights Department in Oxford, UK: phone: (+44) 1865 843830, fax: (+44) 1865 853333, e-mail:
[email protected] You may also complete your request on-line via the Elsevier homepage (http://www.elsevier.com), by selecting 'Customer Support' and then 'Obtaining Permissions' British Library Cataloguing in Publication Data A catalogue record for this book is available from the British Library Library of Congress Cataloguing in Publication Data A catalogue record for this book is available from the Library of Congress ISBN 0 340 73162 1 For information on all Elsevier Butterworth-Heinemann publications visit our website at www.bh.com Transferred to digital printing 2006 Printed and bound by Antony Rowe Ltd, Eastbourne Contents Preface viii 1. Metal processing and manufacturing 1.1 Introduction 1.2 The manufacturing engineering discipline 1.3 Materials used in manufacturing 1.4 Raw materials to finished product 1.5 Primary manufacturing processes - steelmaking 1.6 Primary manufacturing processes - aluminium production 1.7 Secondary manufacturing 1.8 Problems 3 4 4 12 15 16 2. Solidification and casting processes 2.1 Introduction 2.2 Major casting techniques 2.3 Solidification mechanism 2.4 Solidification volume shrinkage 2.5 Heat transfer during solidification 2.6 Defects produced during casting 2.7 Shape casting materials 2.8 Design of shape castings for manufacturing 2.9 Problems 18 18 18 30 36 40 49 57 61 63 Case study 1" Manufacture of can body stock - 1. Casting 67 Case study 2" Cosworth-Ford casting process 72 3. Stress and strain during deformation 3.1 Introducti