- •I.P. Volchok, s.B. Belikov, V.V. Gazha
- •I.P. Volchok, s.B. Belikov, V.V. Gazha, 2008
- •Contents
- •Preface
- •1 Structural materials
- •1.1. Classification and General Properties of Structural Materials
- •Fig. 1.2. The major groups of engineering materials
- •1.2. Mechanical Properties
- •Fig. 1.8. Principle of Brinell hardness test:
- •1.3. Atomic-Crystal Structure of Metals
- •Fig. 1.20. Edge dislocation in a crystal lattice
- •1.4. Solidification and Metal Structure
- •Fig. 1.25. Cooling curves for a pure metal
- •1.5. Phase Diagrams and Structure of Alloys. System of Iron-Carbon Alloys
- •1.6. Heat-Treatment of Steel
- •1.7. Chemical Heat-Treatment (Casehardening) of Steel
- •1.8. Classification and Identification of Iron-Carbon Alloys
- •2 Metallurgy
- •2.1. Materials Used in Metallurgy
- •2.2. Blast-Furnace Process
- •2.3. Steel production
- •2.4. Production of Non-Ferrous Metals
- •2.5. Powder metallurgy
- •3 Foundry practice
- •3.1. Theoretical Fundamentals of Foundry
- •3.2. Manufacture of Castings in Sand Moulds
- •3.3 Shell-Moulding Process
- •3.4. Metal Mould Casting
- •3.5. Centrifugal Casting (Spinning)
- •3.6. Pressure-Die Casting
- •3.7. Investment Casting
- •3.8. Modern Processes of Metal Production for Castings
- •4 Metal forming
- •4.1. Physical and Mechanical Fundamentals of Metal Forming
- •4.2 Recovery and Recrystallization
- •4.3. Technological Plasticity
- •4.4. Heating of Metals
- •4.5. Rolling
- •4.6. Extrusion of Metals
- •4.7. Drawing
- •4.8. Hammering
- •4.9. Die Forging
- •4.10 Stamping
- •5 Welding
- •5.1. The Physical Fundamentals of Welding
- •5.2. Arc Welding
- •5.3. Gas Welding
- •5.4. Resistance Welding
- •5.5. Diffusion Welding
- •6 Metal cutting operations
- •6.1. Principles of Cutting and Shaping the Metals
- •6.2 Geometry of a Cutting Tool
- •6.3. Cutting Speed and Chip Formation
- •6.4. Cutting Materials
- •6.5. Machine Tools Classification
- •6.6. Lathe Works
- •6.7. Drilling
- •6.8. Planing, Shaping and Slotting
- •6.9. Milling
- •6.10. Gear - Cutting Methods
- •6.11. Grinding
- •6.12. Finishing and Microfinishing Processes in Machining of Metals
- •6.13 Electrophysical and Electrochemical Machining
- •Dictionary
- •Bibliography
Preface
This book covers the theoretical aspects of producing metals and non-metals. It will also help you to learn the principles of physico-chemical treatment of materials to manufacture various parts and products. An old adage in materials science says: "materials are like people; it is the defects that make them interesting". The number and the quality of structural or engineering materials, their technology of production and machine tools used determine how much products a country produces and how well its people live.
Perhaps you already know that people have inhabited this planet for about 2.5 million year. Here we mean so-called skillful people who used tools such as wooden sticks and pieces of stone. Let us assume that this period equals 24 hours, which will help us to consider the progress of humanity.
For many years people were food gatherers, eating only berries, eggs and meat left by other animals. Only 250,000 years ago people learned how to make fire. According to our scale it happened 2h 24 min ago. About 20,000 years ago (11.5 min ago) the first complex tool (which had more than one part), supposedly appear for hunting, was evolved. The main part of the fundamental mechanics - the wheel - was invented about 5,500 years ago (that is about 6 minutes ago).
The metallic tools, such as an anvil, an ax, a chisel, a saw with the set of teeth, shears and proportional divider were developed several thousands years ago (that is several minutes ago). Although people had tools, all work was done by either the physical power of men or beasts, and sometimes by waterwheel. The first real machine appeared in 1776. This machine was the steam engine, invented by James Watt (7.5 seconds ago).
The first motor-car, electric lamp, telephone, airplane, photography, etc. were discovered about 100 years ago (3 sec).
Production of Ti and Mg (industrial method), semiconductors, synthetic rubber, TV sets started about 50 years (1.5 sec) ago.
Modern microelectronics, space laboratory and stations, melting and welding in the space the amorphous alloys appeared practically during your life (15 to 20 years) ago (less than 1 sec). You are living in a very interesting period of time - the time of technical revolution. So you have got a chance to do as much as you can for humanity.
Of course, first of all, you must know modern engineering materials and machine tools, which are the basis of the modern mechanized society. You must know the composition of material, its mechanical, physical and chemical properties to select a structural material for manufacturing the machine elements.
The course consists of 6 parts:
structural materials
metallurgy
foundry practice
metal forming
welding
metal cutting operations.
Materials science is an interdisciplinary field involving the properties of matter and its applications to various areas of science and engineering. It includes elements of applied physics and chemistry, as well as chemical, mechanical, civil and electrical engineering. With significant media attention to nanoscience and nanotechnology in the recent years, materials science has been propelled to the forefront at many universities, sometimes controversially.
Material science is very important for you because it gives an overview of the main technical notions and principals that are very important for the future specialists of your major. The main challenge you will face is technical English. This book will help you to learn more than 2000 technical terms. The dictionary in the end of the book summarizes all these words for you with translation into Russian and Ukrainian.
A word of warning and encouragement: Don't worry if you don't understand this book completely on the first reading. We didn't understand it all on the first writing! Remember that this isn't a book to read once and put on a shelf. We hope you'll find yourself referring to it again and again for useful information and for inspiration.