Automotive Manufacturing Processes: A Case Study Approach

Description

"Automotive Manufacturing Processes discusses basic principles and operational procedures of automotive manufacturing processes, issues in the automotive industry like material selection, and troubleshooting. Every chapter includes specific learning objectives, multiple-choice questions to test conceptual understanding of the subject and put theory into practice, review questions, solved problems, and unsolved exercises. It covers important topics including material decision making process, surface hardening processes, heat treatment processes, effects of friction and velocity distribution, the metallurgical spectrum of forging, and surface finishing processes. Features: Discusses automotive manufacturing processes in a comprehensive manner with the help of applications. Provides case studies addressing issues in the automotive industry and manufacturing operations in the production of vehicles. Discussion on material properties while laying emphasis on the materials and processing parameters. Covers applications and case studies of the automotive industry. The text will be useful for senior undergraduate, graduate students, and academic researchers in areas including automobile engineering, industrial and manufacturing engineering, and mechanical engineering"-- Cover Half Title Title Page Copyright Page Dedication Table of Contents Preface Salient Features of the Book Acknowledgements About the Authors Abbreviations 1 Automotive Materials Learning Objectives 1.1 Introduction 1.2 Requirements of Ideal Automotive Materials 1.3 Classification of Materials Used in Automobiles 1.3.1 Metals and Alloys 1.3.2 Ceramics 1.3.3 Glasses and Glass-Ceramic 1.3.4 Polymers (Plastics) 1.3.5 Semiconductors 1.3.6 Composite Materials 1.3.7 Others 1.4 Properties of Automotive Materials 1.5 Ferrous Materials and Their Alloys: Cast Iron and Steels—Types, Properties, and Applications 1.5.1 Cast Iron Classifications 1.5.1.1 Gray Cast Iron 1.5.1.2 White Cast Iron 1.5.1.3 Malleable Cast Iron 1.5.1.4 Nodular Cast Iron 1.5.1.5 Mottled Cast Iron 1.5.1.6 Chilled Cast Iron 1.5.2 Plain Carbon Steel 1.5.2.1 Low-Carbon Steels 1.5.2.2 Medium-Carbon Steels 1.5.2.3 High-Carbon Steels 1.5.3 Alloy Steels 1.5.3.1 Stainless Steels 1.5.3.2 Austenitic Stainless Steels 1.5.3.3 Ferritic Stainless Steels 1.5.3.4 Martensitic Stainless Steels 1.5.3.5 Tool Steels 1.6 Material Selection Process in the Automotive Industry 1.7 Summary 1.8 Review Questions 2 Nonferrous Materials Learning Objectives 2.1 Introduction 2.2 Nonferrous Materials and Their Alloys 2.2.1 Copper and Its Alloys 2.2.1.1 Properties and Uses 2.2.2 Copper Alloys 2.2.3 Aluminium and Its Alloys 2.2.4 Magnesium and Its Alloys 2.2.5 Titanium Alloy 2.3 Ceramics – Properties of Ceramic Materials and Applications 2.4 Polymer Materials 2.4.1 Thermo-Setting Plastics, Rubber 2.4.2 Thermoplastics 2.4.3 Thermosetting Polymers 2.4.4 Applications of Polymers 2.5 Glass Fibre and Carbon Fibre: Properties and Applications 2.5.1 Glass Fibre 2.5.2 Carbon Fibre 2.6 Modern Materials Used in the Automotive Industry 2.7 Material Decision-Making Process 2.8 Business Factors Affecting Material Selection 2.9 Summary 2.10 Review Questions 3 Heat Treatment Learning Objectives 3.1 Introduction: Concept of Phase and Phase Transformation 3.1.1 Concept of Phase 3.1.2 Phase Transformation 3.2 Iron–Iron Carbide Phase Equilibrium Diagram 3.3 Common Heat Treatment Processes and Their Applications 3.3.1 Types of Heat Treatment Processes 3.3.2 Annealing 3.3.3 Normalising 3.3.4 Hardening and Quenching 3.3.5 Tempering 3.4 Surface Hardening Processes: Gas Carburising, Nitriding, Cyaniding 3.4.1 Carburising 3.4.2 Cyaniding 3.4.3 Nitriding 3.4.4 Carbonitriding 3.5 Induction and Flame Hardening 3.5.1 Induction Hardening 3.5.2 Flame Hardening 3.6 Heat Treatment Processes in the Automotive Industry 3.7 Summary 3.8 Review Questions 4 Moulding and Casting Learning Objectives 4.1 Introduction 4.2 Pattern Making 4.2.1 Types of Pattern 4.2.2 Pattern Materials 4.3 Moulding 4.3.1 Classification of Moulding 4.3.2 Green Sand Moulding 4.3.3 Core 4.4 Casting 4.4.1 Permanent Mould Casting 4.4.2 Centrifugal Casting 4.4.3 Pressure Die Casting 4.5 Pouring (Gating Design) 4.5.1 Aspiration Effect 4.5.2 Effects of Friction and Velocity Distribution 4.6 Solved Examples 4.7 Defects in Casting: Causes and Remedies 4.8 Automotive Moulding 4.9 Metal Casting Applications in the Automotive Industry 4.10 Summary 4.11 Unsolved Examples 4.12 Review Questions 5 Forging Process Learning Objectives 5.1 Introduction 5.2 Forging and Forgeability 5.2.1 Forging 5.2.2 Forgeability 5.3 Advantages and Disadvantages 5.4 Forging Tools and Forging Methods: Hand Tools and Forging Operations 5.5 Power Forging: Spring Hammers, Drop Hammers 5.6 Defects in Forged Parts and Their Causes 5.7 Forged Automotive Components 5.8 Metallurgical Spectrum of Forging 5.9 Summary 5.10 Review Questions 6 Welding Process Learning Objectives 6.1 Introduction 6.2 Concept of Welding and Weldability 6.3 Arc Welding: Arc Welding Equipment, Electrodes 6.4 Gas Welding: Types of Flames, Gas Welding Equipment 6.5 Resistance Welding: Types and Applications 6.6 Design of Weld Joints, Butt Joints, Fillet Joints 6.7 Strength of Transverse Fillet Welds 6.8 Solved Examples 6.9 Allied Processes: Soldering, Brazing 6.10 Special Welding Processes: Plasma Arc Welding, Metal Inert Gas Arc Welding (MIG), TIG Welding 6.11 Automotive Applications of Welding 6.12 Welding Procedure for Automotive Manufacturing 6.13 Summary 6.14 Unsolved Examples 6.15 Review Questions 7 Material Removal Processes Learning Objectives 7.1 Introduction 7.2 Mechanics of Metal Cutting 7.2.1 Mechanism of Chip Formation 7.2.2 Discontinuous Chips Or Segmental Chips 7.2.3 Continuous Chips With Built Up Edge 7.2.4 Serrated Chips 7.2.5 Types of Metal Cutting Processes 7.3 Cutting Tools 7.3.1 Cutting Tool Geometry 7.3.2 Tool Signature 7.4 Cutting Tools Materials 7.5 Advanced Cutting Tool Materials 7.5.1 Coated Carbides 7.5.2 Cermets 7.5.3 Coronite 7.5.4 High-Performance Ceramics (HPC) 7.5.5 Plain Nitride Ceramics Tools 7.5.6 SIALON Tools 7.5.7 Nitrite Toughened 7.5.8 Zirconia Toughened Alumina (ZTA) 7.5.9 Cubic Boron Nitride (CBN) 7.5.10 Diamond 7.5.11 Polycrystalline Diamond (PCD) 7.5.12 Diamond-Coated Carbide Tools 7.5.13 Carbon With Diamond-Like Properties (DLC) 7.5.14 Carbonado 7.5.15 Extra-Large Synthetic Diamond 7.6 Tool Coating Process 7.7 Tool Failure 7.8 Cutting Forces and Power Consumption 7.8.1 Chip Thickness Ratio (Or Cutting Ratio) 7.8.2 Velocity Relationship in Orthogonal Cutting 7.8.3 Forces Acting On the Chip in Orthogonal Cutting (Merchant’s Analysis) 7.8.4 Stress and Strain On the Chip 7.8.5 Forces of a Single-Point Tool 7.8.6 Popular Theories On the Mechanics of Metal Cutting 7.8.7 Tool Life 7.8.9 Factors Affecting Tool Life 7.9 Coolant Technology 7.9.1 Types of Cutting Fluids 7.10 Reconditioning of the Tools 7.11 Special Case Study: Development of a Hybrid Tool for Boring, Reaming and Chamfering Operation 7.11.1 Introduction 7.11.2 Development of the Tool 7.11.3 Conclusion 7.12 Solved Examples On Tool Life, Machining Forces 7.13 Summary 7.14 Unsolved Examples 7.15 Review Questions 8 Plastic Processing in the Automotive Industry Learning Objectives 8.1 Introduction 8.2 Extrusion of Plastics 8.2.1 Types of Extrusion Process 8.3 Injection Moulding – Plunger and Screw Machines 8.3.1 Screw Type Injection Moulding Machine 8.3.2 Plunger Type Injection Moulding 8.4 Compression Moulding 8.5 Transfer Moulding – Typical Industrial Applications 8.6 Blow Moulding 8.7 Advanced Plastics Used in the Automobile Sector 8.8 Usage and Advantages of Plastic Components in the Automotive Industry 8.9 Summary 8.10 Review Questions 9 Powder Metallurgy Learning Objectives 9.1 Introduction 9.2 Production of Metallic Powder 9.3 Processing Methods 9.4 Advantages and Disadvantages 9.5 Secondary Operations 9.6 Automotive Applications of Powder Metallurgy 9.7 Summary 9.8 Review Questions 10 Surface Treatment Learning Objectives 10.1 Introduction 10.2 Selection and Use of Surface Treatment and Cleaning Processes 10.3 Surface Cleaning Processes: Sand Blasting, Tumbling, Alkaline, Acid and Electrolytic Cleaning 10.4 Surface Coating Processes: Electroplating, Galvanising, Metal Spraying, Painting 10.5 Automotive Painting Process, Ingredients, Painting Procedure 10.6 Surface Finishing Process: Polishing, Buffing, Burnishing, Super Finishing 10.7 Surface Treatments for Automotive Manufacturing 10.8 Applications of Surface Treatments in the Car Industry 10.9 Summary 10.10 Review Questions 11 Press Shop Process Learning Objectives 11.1 Introduction 11.2 Sheet Metal Working: Bending, Forming and Deep Drawing 11.2.1 Bending 11.2.2 Forming 11.2.3 Deep Drawing 11.3 Difference Between Punching, Piercing and Blanking 11.3.1 Punching 11.3.2 Piercing 11.3.3 Blanking 11.4 Mechanics of the Forming Process 11.5 Determination of the Drawing Force and Power 11.6 Determination of Maximum Allowable Reduction 11.7 Determination of Work Load 11.8 Solved Examples 11.9 Press – Types, Construction and Working 11.9.1 Types of Presses 11.9.2 Construction 11.10 Press Tools – Dies, Punches 11.10.1 Dies 11.10.2 Punches 11.11 Automotive Stamping Manufacturing Process 11.12 Identification of Major Auto Components By Material and Process 11.13 Summary 11.14 Review Questions 12 Case Studies of Automotive Manufacturing Units Learning Objectives 12.1 Case Study 1: Heat Treatment of Automotive Components – Current Status and Future Trends 12.1.1 Introduction 12.1.2 Materials and Their Applications in Automobiles 12.1.2.1 Bake Hardening Steel Sheets 12.1.2.2 High-Tensile-Strength Steel Sheets 12.1.2.3 Corrosion-Resistant Coated Steel Sheets 12.1.2.4 Constructional Steels 12.1.2.5 Case Hardening Steels 12.1.2.6 Heat-Resistant Steels 12.1.2.7 Copper Alloys 12.1.2.8 Aluminium Alloys 12.1.2.9 Magnesium Alloys 12.1.2.10 Titanium Alloys 12.1.2.11 Composite Materials 12.1.2.12 Plastics and Rubber 12.1.2.13 Glass and Ceramics 12.1.3 Heat Treatment 12.1.3.1 Types of Heat Treatment 12.1.3.2 Processing Technology in Heat Treatment 12.1.3.3 Carburising and Carbonitriding 12.1.3.4 Nitrocarburising 12.1.3.5 Induction Hardening 12.1.3.6 Powder Metallurgy and Sintering 12.1.4 Key Issue in Heat Treatment: Atmosphere Control 12.1.4.1 Carbon Potential Control 12.1.4.1.1 Gas Carburising Processes 12.1.4.1.2 Reduced Pressure Carburising (Vacuum Carburising) 12.1.4.1.3 High-Pressure Gas Quenching 12.1.4.1.4 Carbonitriding 12.1.4.1.5 Low-Temperature Nitrocarburising and Oxy-Nitrocarburising 12.1.5 Surface Modification and Treatment 12.1.5.1 Coatings of Solid Lubricant 12.1.6 Emerging Technologies in Materials, Heat Treatment and Surface Processing Operations 12.1.6.1 Materials 12.1.6.2 Carburising and Carbonitriding 12.1.7 Conclusion 12.2 Case Study 2: Casting in the Automotive Industry 12.2.1 Introduction 12.2.2 Automotive Manufacturing and Die Casting 12.2.3 HID Light Ballast Unit Housing 12.2.4 Transmission Range Control Module (TRCM) Housing 12.2.5 Ford Hydra ECU Housing 12.2.6 Conclusion 12.3 Case Study 3: Performance of Forging 12.3.1 Introduction 12.3.2 Conclusion 12.4 Case Study 4: Automotive Applications of Welding Technology 12.4.1 Introduction 12.4.2 Automotive Applications of Welding 12.4.2.1 Resistance Spot Welding 12.4.2.2 Resistance Seam Welding 12.4.2.3 Friction Welding 12.4.2.4 Medium-Frequency Welding 12.4.2.5 Magnetic Pulse Welding 12.4.3 Conclusion 12.5 Case Study 5: Machining Operation in the Automotive Industry 12.5.1 Introduction 12.5.2 Study Framework 12.5.3 SMED Implementation Program 12.5.3.1 Separate Internal and External Setups 12.5.3.2 Stage 3 (Streamline Operations) 12.5.4 Conclusion 12.6 Case Study 6: Automotive Plastic Processing 12.6.1 Introduction 12.6.1.1 Polyvinyl Chloride 12.6.1.2 Polypropylene 12.6.1.3 ABS 12.6.1.4 Polyamide 12.6.1.5 Polystyrene 12.6.1.6 Polyoxymethylene (POM) 12.6.1.7 Polycarbonate 12.6.1.8 Polyethylene 12.6.2 Conclusion 12.6.3 Review Questions Multiple Choice Questions (MCQs) With Answers and Necessary Explanation Chapter 1: Automotive Materials Chapter 2: Nonferrous Materials Chapter 3: Heat Treatment Chapter 4: Moulding and Casting Chapter 5: Forging Process Chapter 6: Welding Process Chapter 7: Material Removal Processes Chapter 8: Plastic Processing in the Automotive Industry Chapter 9: Powder Metallurgy Chapter 10: Surface Treatment Chapter 11: Press Shop Process Chapter 12: Case Studies of Automotive Manufacturing Bibliography Index