Metal Shaping Processes. Vukota Boljanovic

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       METAL SHAPING PROCESSES:

       Casting and Molding; ParticulateProcessing; Deformation Processes;and Metal Removal

       VUKOTA BOLJANOVIC, Ph.D.

       Industrial Press, Inc.

       New York

COPYRIGHT

      Library of Congress Cataloging-in-Publication Data

      Boljanovic, Vukota.

      Metal-shaping Processes / Vukota Boljanovic.

      p. cm.

      ISBN 978-0-8311-3380-1 (hardcover)

      1. Metal-work. I. Title.

      TS205.B585 2009

      671.3–dc22

      2009001061

      Industrial Press, Inc.

      989 Avenue of the Americas

      New York, NY 10018

      Sponsoring Editor: John Carleo

      Interior Text and Cover Design: Janet Romano

      Developmental Editor: Kathy McKenzie

      Copyright © 2010 by Industrial Press Inc., New York. Printed in the United States of America. All rights reserved. This book, or any parts thereof, may not be reproduced, stored in a retrieval system, or transmitted in any form without the permission of the publisher.

      10 9 8 7 6 5 4 3 2 1

      The reproduction of cover images is through the courtesy of Alcoa Inc.

      Ingot, Warrick, Indiana USA,

      Sheet, Warrick, Indiana USA,

      Smelter Wenatchee, Washington USA

      Loop Control Pit, The Flat Rolled Product division of Alcoa-Kofem Kft.

      Szekesfehervar, Hungary.

DEDICATION

      To those who inspire me — my family and my friends

      CONTENTS

       Cover

       Title Page

Copyright

Dedication

Preface

Introduction

General Processes Overview

Classification of Shaping Processes

Production Equipment and Tooling

PART ICASTING AND MOLDING

       Chapter 1Fundamentals of Metal Casting

1.1Introduction

1.2Heating the Metal

1.3Pouring the Molten Metal

1.3.1Engineering Analysis

1.4Fluidity

1.4.1Test for Fluidity

1.5Solidification and Cooling of Metals

1.5.1Solidification Time

1.5.2Shrinkage

1.6Defects in Casting

       Chapter 2Metal Casting Processes

2.1Introduction

2.2Sand Casting

2.2.1Foundry Sands

2.2.2Patterns

2.2.3Cores

2.2.4Types of Sand Molds

2.2.5Sand Molding Techniques

2.2.6The Sand Casting Operation