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ABOUT THE BOOK

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 processes, 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 undergraduates, graduate students and academic researchers in areas including automobile engineering, industrial and manufacturing engineering and mechanical engineering.

TABLE OF CONTENTS

1. Auto Materials. 1.1 Introduction. 1.2 Requirement of ideal Auto materials. 1.3 Classification of materials used in Automobiles. 1.4 Properties of Auto materials. 1.5 Ferrous materials and its alloys: Cast Iron and Steels – Types, their properties and applications. 1.6 Material selection process in Automotive Industry. 2. Nonferrous materials. 2.1 Introduction. 2.2 Nonferrous materials and its alloys: Copper, Brass, Bronze, babits, Aluminium and Magnesium, their properties & applications. 2.3 Ceramics -Properties of ceramic material and applications. 2.4 Polymers materials. 2.5 Glass fibre and carbon fibre: Properties and applications. 2.6 Modern materials used in auto industry. 2.7 Material decision making process.  2.8 Business factors affecting material selection.  3. Heat Treatment. 3.1 Introduction: Concept of phase and phase transformation. 3.2 Iron-Iron carbide phase (Fe-fe3C) equilibrium diagram. 3.3 Common heat treatment processes and their applications; Annealing, Normalizing, Hardening, Tempering. 3.4 Surface hardening processes: Gas carburizing, Nitriding, Cyaniding. 3.5 Induction and Flame hardening. 3.6 Heat Treatment processes in Automotive Industry. 4. Moulding and Casting. 4.1 Introduction. 4.2 Pattern making: Types and materials.  4.3 Moulding : Classification of moulding, Green sand moulding and Cores. 4.4 Casting: Permanent mould casting, centrifugal casting process and Die-casting process. 4.5 Casting defects, causes and remedies. 4.6 Solved Examples.  4.7 Defects in casting: causes and remedies. 4.8 Automotive Moulding. 4.9 Metal casting applications in Automotive Industry. 5. Forging Process. 5.1 Introduction. 5.2 Forging and Forgeability. 5.3 Advantages, disadvantages.  5.4 Forging tools and forging method: Hand tools,  forging operations. 5.5 Power Forging: Spring hammer, Drop hammers. 5.6 Defects  in forged parts and their causes. 5.7 Forged Automotive components. 5.8 Metallurgical Spectrum of forging. 5.9 Forging Spectrum for a similar alloy. 6. Welding Process. 6.1 Introduction. 6.2 Concept of weld and weldability. 6.3 Arc welding: Arc welding equipments, Electrodes. 6.4 Gas welding:  Types of  flames, Gas welding equipments. 6.5 Resistance welding :Types  and applications.  6.6 Design of weld joints, butt joint, fillet joints. 6.7 Strength Of Transverse Fillet Welds. 6.8 Solved examples. 6.9 Allied Processes: Soldering, Brazing. 6.10 Special welding process: Plasma arc welding, Metal inert gas arc welding (MIG), TIG welding. 6.11 Automotive applications of welding. 6.12 Welding procedure for Auto Manufacturing. 7. Material Removal Processes. 7.1 Introduction.  7.2 Mechanics of metal cutting. 7.3 Cutting tools. 7.4 Cutting tools material. 7.5 Advanced cutting tool materials. 7.6 Tool coating process. 7.7 Tool Failures. 7.8 Cutting forces and power consumption. 7.9 Coolant Technology. 7.10 Reconditioning of the tools. 7.11 Special Case study: Development of Hybrid Tool for Boring, Reaming and Chafering Operation. 7.12 Solved examples on tool life, machining forces. 8. Plastic processing in Auto Industry. 8.1 Introduction. 8.2 Extrusion of plastics. 8.3 Injection moulding – Plunger and screw machines. 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 Advantage of plastic component in Automotive Industry. 9. Powder Metallurgy. 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. 10. Surface treatment. 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, galvanizing, metal spraying, painting. 10.5 Automotive painting process, ingredients, painting procedure. 10.6 Surface finishing process- polishing, buffing, burnishing, super finishing. 10.7 Surface Treatment for automotive manufacturing. 10.8 Automotive Industry: Performance driven surface treatment technologies. 10.9 Applications of Surface treatment in car industry. 11. Press shop process. 11.1 Introduction. 11.2 Sheet metal working: Bending, forming & deep drawing. 11.3 Difference between Punching, piercing & blanking. 11.4 Mechanics of 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 & working. 11.10 Press tools-Dies, punches. 11.6 Automotive Stamping manufacturing process. 11.7 Identification of major auto components by material and Process. 12. Case studies of Automotive Manufacturing Units. 12.1 Heat Treatment of Auto components: Case study. 12.2 Case study of casting in Automotive Industry. 12.3 Performance of Forging- A case study. 12.4 Automotive Welding- a case study. 12.5 Machining Operation in Automotive Industry- a Case Study. 12.6 Automotive plastic processing- a Case Study.