Automotive Manufacturing Processes A Case Study Approach

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.

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 exampleson 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.

Dr. G. K. Awari has done his Ph.D. in Mechanical Engineering and he has more than 30 years of teaching experience at UG/PG/Diploma & Research level and 10 years as an approved Principal of A+ Grade NAAC Accredited Engineering Institute. He is nominated by AICTE as “Margdarshak for NBA Accreditation” of mentee institutes and also working as “Chief Coordinator” of AICTE Mentor institutes for achieving NBA Accreditation to MBI. He has more than 30 Scopus Indexed Journal papers and 10 Patents, 10 Copyrights, to his name. Recently he has been awarded with Patent titled as “HYBRID TOOL CONCEPT FOR BORING, REAMING & CHAMFERING IN A SINGLE TOOL” and Commercial Product is developed for Mahindra and Mahindra, Nagpur. He has been also granted with an Australian Patent on “3D PRINTING of COST EFFECTIVE HUMAN SKULL MODELS AND SKULL INPLANTS”. He has executed more than 8 funded projects of AICTE as a Principal Investigator and organised 10 AICTE-ISTE-SRM University funded National Workshops and 10 International Conferences as a convener. Total grants received for his projects are Rs. 1.14 Crore. He has contributed in the development Academics/Curriculum as Board of Study (BOS) Member at Goa University, Sant Gadgeba Amravati University, YCCE, Nagpur (An Autonomous Institute) and RTM Nagpur University. He is presently BOS member in GH Raisoni University, Saikheda, MP, Delhi Skill and Entrepreneurship University (DSEU), New Delhi and Chairman BOS, Automobile Engineering at Government Polytechnic (GP), Nagpur. He has authored total 10 Books in Engineering and Technology domain and following four books are authored for CRC Press, Taylor and Francis Group. 1. Quantitative Techniques in Business, Management and Finance: A Case study approach.2. Automotive Systems: Principles and Practice. 3. Additive Manufacturing and 3D Printing Technology: Principles and Practice.4. Ethics in Information TechnologyDr. Awari is recognised Research Supervisor at 4 Indian universities. Total 18 (eighteen) research scholars completed PhD in Mechanical Engineering under his supervision from RTM Nagpur University and SG Amravati University. Currently 06 research scholars are pursuing doctoral research work under his supervision. He is also reviewer of various renowned international journals like ASME, ASCE, and Elsevier, Thermal Science. Dr. Awari belives in the Co-learning Process and Participative management and currently he is Head of Automobile Engineering Department at Government Polytechnic, Nagpur. Prof. V.S.Kumbhar received Bachelor of Engineering and Master of Engineering degree in Automobile engineering from Shivaji University Kolhapur, Maharashtra, India in 2007 and 2013 respectively. He has total 14 years of experiences. (04 years of industrial experience in automobile manufacturing engineering and 10 years of teaching experience at undergraduate level.) He has taught various subjects like Automobile engines, Automobile systems, Automobile Design, Machine design, Strength of materials, Advanced Engines and Automobile Engineering. His area of interest is fuels and combustion, emission control systems. He has more than 11 international journal publications to his credit and authored a book on “Automotive Systems” for CRC Press, Taylor and Francis Group. He has contributed in the development of Academics as Subject expert for Maharashtra State Board of Technical Education, MSBTE, Mumbai and at Government Polytechnic, Nagpur. He had contributed in academics as BOS member of Automobile Engineering at Government Polytechnic (GP), Nagpur. Prof. Kumbhar is pursuing Ph.D. in Mechanical Engineering at GH Raisoni university, Amravati and currently he is working at Automobile Engineering Department of Government Polytechnic, Awsari Khurd. Dr. R. B. Tirpude received Bachelor of Engineering degree in Mechanical Engineering from RTM Nagpur University, Nagpur, Maharashtra, India in 1998, M.E. degree in CAD/CAM from Sant Gadgebaba Amravati University, Amravati, Maharashtra, India, in 2008 and Ph.D. in Mechanical Engineering in 2022 from RTM Nagpur University, Nagpur. He has done his MBA (operations) from Delhi university Delhi, India, in 2012. He has total 21 years of teaching experience at undergraduate, research level. He has taught various subjects like Computer Aided Drafting, Hydraulics and Pneumatics, Operation research, Fluid Power, Machine Design and Automobile Engineering. His area of interest is emission control system He has total 19 international journal publications, 10 international conference publications and 11 national conference publications and 10 patents to his name. He has also authored a book on “Automotive Systems” for CRC Press, Taylor and Francis Group. He has been honoured with “ISTE Narsee Munji Best Project Award” and “Shastri Gaurav Purskar-2022. He is also a recipient of “Best Teacher Award” from Government polytechnic Nagpur as well as Dr. Babasaheb Ambedkar National Association of Engineers, Nagpur chapter. He has