.'"" WESTERMANN TABLES FortheMetalTrade Materials· NumericaOl uantities· Forms REVISEDTOINDIAN STANDARDS REVISEDSECONDEDITION Edited by Hermann Jiitz and Eduard scharkus PUBLISHING FOR ONE WORLD NEW AGE INTERNATIONAL (P).LIMITED, PUBLISHERS .(formerlY Wiley Eastern Limited) New Delhi. Bangalore . Chennai . Cochin. Guwahati . Hyderabad Jalandhar . Kolkata. Lucknow. Mumbai . Ranchi Visit usatwww.newagepublishers.com Materials-Numerical Q\ vocational schools as well for use primarily by the af been made to shorten the I that its contents are readil) Much painstaking eff( .yright~ 2006, 1966, NewAgeInternational(P)Ltd.,Publishers selected that the reader can lished byNew Age International(P) Ltd., Publishers decision of either selecting tEnglishEdition: 1966 compilations can be as har 'isedSecondEdition :2006 Not only the selectior 'isedto IndianStandardby SKIP: 1976 contents of the tabular COI decide where to look for p The authors and publi~ rightsreserved. suggestions for improving partofthisbookmaybereproduced inanyform,byphotostat, microfilm,xerography,or other means, or incorporated into any information retrieval system, eh:ctronic or :hanicai,without the written permission ofthe copyrightowner. Braunschweig and Northeim IN: 81-224-1730-2 .125.00 06-03-659 pesetat Le-Studio, Gurgaon. ntedinIndiaatMehraOffset. BLiSHING FOR ONE WORLD !:WAGE INTERNATIONAL(P) LIMITED, PUBLISHERS 71IergWi/!)'&/em Lif11ileJ) - 35/24, Ansari Road, Daryaganj, New Delhi 110002 situs at www.newagepublishers.com Preface Materials-Numerical Quantities-Fonns- Tables compiled for the metal trade are dedicated to vocationalschools as well as to practical usage at the job site. Although the tables have been compiled foruse primarily by the apprentice, the specialized worker will also find them useful. Every effort has beenmade to shorten the sometimes tedious operations and the arrangement of subject matter is such thatits contents are readily available to the practical man. Much painstaking effort must go in compiling and arranging such tables. Infonnation must be so selectedthat the reader can, from the bulk of material, easily find out the subject of his interest. Often, a decisionofeither selecting anitem or rejecting itproves difficult. Too much material packed into tabular compilations can be as hannful a~the omission of some vital pieces of infonnation. Not only the selection but also the arrangement of material requires considerable thought if the contents of the tabular compilations have to be offered for ready reference. Only then can the reader decidewhere to look for proper infonnation. The principle of order must be evident at once. The authors and publishers hope that they have succeeded in fulfilling their special tasks. However, suggestions for improving the tabular compilations are welcome. HERMANN J(JTz Braunschweig EDUARDSCHARKUS andNortheim Table of Contents SECTION ONE Materials 1-27 SECTION Two Numbers 28-63 -. SECTION THREE Mechanics 64-75 SECTION FOUR EngineeringComponents 76-93 SECTION FIVE MetalCuttingOperations 94-127 SECTION SIX EngineeringDrawings 128-147 Index 148-150 151 Measures and Weights Westermann Tables Materials Classificationandcategories 0 0 9 Ferrousmetals E? ferrous metals Structural Tool Cast Malleable Copper,Lead PVC steel steel steel iron iron Zinc,Tin, White- Nickel. AI Vulcani- heart zedfibre CaIbon CaIbon Grey malleable Copperalloys steel toolsteel castiron iron ZAinIcaallloloyyss Amino- Black- plasts heart Astleloely toAolllsotyeel caAsltloiryon malleable Solders Phenol- iron plasts General properties of materials Chemical elements Specific weight-Melting points-Coefficient of linear (thenna\) expansion Sym- Element Specific Melting Coefficient Sym- Element Specific Melting Coefficient bol weight or solidi- of linear bol weight or solidi- of linear - gflemJ fication (thermal) gflemJ fication (thermal) point expansion point expansion °C a °C a Ag Silver 10.5 961 0.000 020 Ni Nickel 8.9 1453 0.000 013 AI Aluminium 2.7 660 0.000 024 P Phosphorus 1.82 44 0.000 124 Au Gold 19.3 1063 0.000 014 Pb Lead 11.35 327 0.000 029 Ba Barium 3.74 704 PI Platinum 21.45 1769 0.000 009 Be Beryllium 1.85 1283 0.000 012 Ra Radium 5.00 700 Bi Bismuth 9.75 271 0.000 013 S Sulphur 2.06 113 0.000 064 C Carbon Sb Antimony 6.69 630 0.000 011 Graphite 2.25 3550 0.000 008 Se Selenium 4.5 217 0.000 037 Diamond 3.52 3600 0.000 001 Si Silicon 2.4 1410 0.000 008 Ca Calcium 1.55 850 Sn Tin 7.3 232 0.000 023 Cd Cadmium 8.64 321 0.000 029 Ta Tantalum 16.6 3030 0.000 007 Ce Cerium 6.9 775 Th Thorium 11.2 1827 0.000 011 Co Cobalt 8.8 1492 0.000 013 Ti Titanium 4.52 1812 0.000 009 Cr Chromium 7.1 1800 0.000 007 U Uranium 18.7 1132 Cu Copper 8.9 1083 0.000 017 V Vanadium 5.96 1730 Fe Iron 7.86 1535 0.000 012 W Tangsten 19.27 3380 0.000 004 1r Iridium 22.42 2443 0.000 006 Zn Zinc 7.13 420 0.000 026 K Potassium 0.86 63 0.000 084 Zr Zirconium 6.5 1852 0.000 005 La Lanthanum 6.18 826 Hg Mercury 13.5 - 39 Li Lithium 0.53 180 0.000 058 CI Chlorine - 101 Mg Magnesium 1.74 650 0.000 026 H Hydrogen - 259 Mn Manganese 7.3 1244 0.000 023 He Helium -272 Mo Molybdenum 10.21 2610 0.000 005 N Nitrogen -210 Na Sodium 0.97 98 0.000 071 Ne Neon ..:.249 Nb Niobium 8.55 2415 0.000 007 0 Oxygen - 219 2 WestermannTables SpecificWeigbt-MeltingPoint--CoeffidentofThennalExpansioo--Shrie = Specific weight Weightperunit volume(gf/cm' orkgf/dm3) EO it = -- -. Meltingpoint (Fusionpoint) Temperature at whichparticular material startsmelting -r = Coefficientoflinear (thermal) Increase inlengthofunit lengthofa expansion a solidfortemperature riseof 1°C. Materials Material Specific weight Meltingpoint °C Material Coefficient of gflem' linear expansion Steel 7.85 1350...1450 Ironand Steel 0.000 012 j Cast steel 7.85 Chrome steel 0.000 010 Greycast iron 7.2 1150...1250 Nickel steel 0.000 012 High-speed steel 9.0 =2000 Tungsten carbide 0.000 006 Tungsten carbide 14.75 =2000 Invar 0.000 0015 Constantan 8.89 =1600 Chromium 0.000 007 Invar (36%Ni) 8.7 1450 Constantan 0.000 015 Brass 8.5 = 900 Electron 0.000 024 I AIbronze 8.4 Aluminium 0.000 023 I AIcastbronze 7.6 Magnesium 0.000 026 Tin bronze 8.6 = 900 Gold 0.000 014 I Lead bronze 9.5 Silver 0.000 019 AI-alloy (AI,Cu, Mg) 2.8 = 650 Zinc 0.000 030 Mg-alloy 1.8 = 650 Tin 0.000 023 Babbitt metal 7.5...10.1 300...400 Lead 0.000 029 Plexiglass 1.2 Nickel 0.000 013 Platinum 0.000 009 Alcohol at 18°C 0.79 -110 Brass 0.000 018 Petrol at 15°C 0.72 -150 Brouce 0.000 017 Copper sulphate 1.11 Plexiglass 0.000 010 I Waterat4°C 1.0 0 Glass I 0.000 008 Porcelain 0.000 003 Acetylene atO°C 1.17kglm3 -84 II i Carbon dioxide atO°C 1.90kglm3 -78 AiratO°C 1.29kglm3 -194 ,,Propane at O°C 2.00 kglm3 -43 = , Shrinkage difference in volumeofthemould compared withthe I volumeofthe castingafter cooling, inpercent Material Shrinkage Material Shrinkage Greycastiron 1% Brass 1.5% I Cast steel 2% Copper 1% Malleable iron 1.6% Tin, lead 1% I Brouce 1.5% Zinc alloys 1.5% Gun metal 1.5% AI,Mg alloys 1.25% Westennann Tables 3 System of Designation or Iron and Steel 18:1762-1961 18:4843-1968 Steel - I I - <0.5% Silicon >0.5% Plaincarbonsteels I- <0.8% Manganese >0.8% H Alloysteels I <0.1% AlorTi >0.1 % -<0.25% orCopper >0.25-% I I Steels Steels LowaUoysteels High alloysteels notrequiredto requiredto receive receive Carbon toolsteels <5%special >5% special heattreatment heattreatment alloyingelement alloyingelement The System ofDesignation isasfollows 1.Letter St I. Letter CforCarbon Letter TforTool steels I. Average Ccontent inhundredths ofapercent without 2.Minimum 2.Index number for Index number for Car- prefix Cand with prefix T forAlloy Tool Steels tensile carbon following bon following letter T, 2.Chemical symbols ofthesignificant elements arranged strength in letter C, denoting denoting average indescending order ofpercentage contents kgf/mm' average Carbon Carbon content inhun- 3.Alloy Index indicating theaverage percentage ofeach content inhundredths dredths ofapercent alloying element ofapercent e.g. SI.42 e.g. C35 e.g. T90 e.g. 15Cr 65 Chrome e.g. 20 Cr 18Ni 2Chrome Steel having a Carbon steel Tool steel steel with average Nickel Steel with average minimum ten- having an having an percentages ofC=0.15 percentages ofC=0.20; sile strength of average of average of and Cr =0.65 Cr= 18andNi= 2.00 42 kgf/mm' 0.35% Carbon 0.90% Carbon Applicable for Steels with special Toindicate.the treat- Alloy index number isassigned as follows: steels which are limits formaximum ment given tothe Nominalor standardized on S&P,receive the steel, symbols are averagealloy Alloyindexnumber thebasis oftheir suffix "K", e.g. used, e.g. T90a,"a" content tensile strength C35K isused to indicate an- i.UptoIpercent. Averagealloycontentupto2decimal without detailed nealing (ref. Page placesunderlinedbyabar chemical com- 4,Add. symbols) 2.Ipercentand Roundedtothenearestwholenumber. position over. Upto0.5roundeddown,0.5andover roundedup. System of Designation ICastings I System ofDesignation ofPlain Castings ofAlloy Castings I. Symbols indicating thetype ofcastings I. Symbols indicating thetype ofcastings 2.Symbol formechanical properties 2.Average carbon content inhundredths of OR apercent following the type symbols of castings I. Symbols indicating thetype ofcastings 3.Chemical symbols for thesignificant 2.Symbol forchemical composition similar elements arranged indescending order tothe designation ofsteels 4.Alloy index number for theaverage percentages ofalloying elements CS-SteelCastings FG-GreyIronCastings SG-SphericalorNodular MalleableIronCastings GraphiteIronCastings CS125-Unalloyed steelcastingswith FG15-Grey ironcastingswith SG8012-Spheroidal orNodu- BM35-Black heartmalleable minimumtensilestrength 125kgf/mm' minimumtensilestrength 15 largraphiteironcastingswith ironcastingswithminimum CSM35-Unalloyed specialsteelcast- kgflmm' minimumTensilestrength80 tensilestrength35kgf/mm' ingswithminimumtensilestrength FG35Si 15-Special greyiron kgf/mm' andminimumelongatio PM70--Pearlitic malleableiron 35kgflmm' castingswithminimumtotal 2%ongaugelengthequaltofive castingswithminimwntensile OS50CrIV20--Alloy steelcastings carbon percentage =3.5 and timesthediameteroftestbar strength70kgf/mm' withaveragepercentage averageSiliconpercentage WM42-White heartmalleable: = = = = ofC 0.50; Cr 1.00; V 2.20 1.50 ironcastingswithminiBrIIm tensilestrength42kgfImm' CSH-Heat resistantsteelcastings AFG-Austenitic flake ASG-Austenitic spheroidalor ABR-AbrasiOll resistantiron CSC-Corrosion resistantsteelcastings graphiteironcastings nodUlargraphiteironcastings castings Tensile strengths are on 30 nun Dia Test Bars as-cast. 4 Westermann Tables Additional symbols Denotingspecialproperties Steelquality Treatmentgiven A-Non-ageing quality R-Rimming quality a-Annealed orsoftened o-Spherodized E-Stabilized againststresscorrosion Grmnsizecontrolled c-Case carburized p-Patented L-Control cooledtoensurefreedomfromflakes H-Hardenability controlled .d-Hard drawn,coldreduced q-Hardened andtempered D-Fully killed I-Inclusion controlled h-Hot-rolled s-Stress relieved D,-Senti killed M-Structural homogeneity n-Normalized t-Tempered guaranteedbyMacro-etchtest e.g.,St42An-Non-ageing steelwith42kgf/mm' 15Cr3c-Chrontium steelwithaveragepercentages = = Ipinimum tensile strength-normalizedof C 0.15. Cr 3.0 and case carburized E-Electric FurnaceSteel;R-Open HearthSteel;BO-Basic Oxygen Grey iron castir1p IS:210-1970 Tranwerse test Codefor Grades Tensilestrength Breakingload Correspondingtranwerse Deflection Typicalapplications designation Min.kgflmm' Min.kgf rupturestresskgflmm' Min,mm FG 15 15 15 800 34.0 4.0 Partsrequiringnospecialgmdesforgeneml FG20 20 20 900 38.2 4.5 structuralpurposes FG25 25 25 1000 42.4 Partssubjectedtoseverestrmnssuchas FG30 30 30 lloo 46.7 55..50} cylinderparts,etc. FG35 35 35 1350 57.3 } FG40 40 40 1500 63.7 55..55 Forextraordinaryuse IS:2108-1962 Malleable iron castir1p IS:2640-1964 IS:2107-1962 Codefor Grades Tensilestrength. 0.5%Proof Elongation%(gauge Brinell Phosphorous Typicalapplications designation Min.kgflmm' stress.Min. length =3dia of hordness contact kgflmm' testbar..)Min HBMax %Max BM35 A 35 2-1 14 149 0.12 Thinwalledcastings;mass BM30 C 30 6 163 0.20 productionpartswheels, PM70 A 70 55 2 241to285 0.12 keys,Partsforlocksand PM45 E 45 28 7 149to201 0.12 sewingmachineparts. WM42 A 42 26 4 217 0.15 WM35 B 35 - 3 217 0.15 Steel castir1p IS:1030-1962 Codefor Grades Tensilestrength Elongation%ongauge S%Max P%Max Typicalapplications designation Min,kgflmm' length5.65 .Min. CS55 I 55 12 0.060 0.060 Usedforgeneralengineeringpurposesinsteadofgrey CS47 2 47 17 0.060 0.060 ironcastingsifgreaterstrengthandtenacityare CS41 3 41 18 0.060 0.060 tobemet. CS65 I 65 17 0.050 0.050 Highstrength,goodtoughnessandhighabrasion CS85 2 85 12 0.050 0.050 resistanceproperties;usedintransportation CS 125 3 125 5 0.050 0.050 equipmentandagriculturalmachineryparts. IS:3038-1965 Alloy steeI castir1p for high temperature service IS:2856-1964 Grades Tensile Elongation% Yieldstress C% Si% Mn% S% P% Typicalapplication.. strength on5.56 gauge or0.5%proof Max Max Min,kgflmm' length.Min stressMin.kgflmm' I 55 17 35 0.20-0.25 0.1.40 1.25-1.45 0.050 0.050 Castpartswhich 2 47 17 25 0.25Max 0.20-0.50 0.50-1.00 0.050 0.050 preferablyareto 3 52 15 31 0.15Max 0.40Max 0.40-0.80 0.050 0.050 withstandtempemtures 4 49 17 28 0.20Max 0.60Max 0.50-0.80 0.050 0.050 between300°Cto 5 52 17 31 0.08-0.15 0.35Max 0.30-0.70 0.050 0.050 525°C 6 63 15 43 0.20Max 0.75Max 0.40-0.70 0.050 0.050 7 63 15 43 0.20Max 1.00Max 0.30-0.70 0.050 0.050 CSN-C20 42 20 21 0.25Max 0.60Max 0.70Max 0.050 0.050 Partswhichtobe CS.-C25 49 18 25 0.30Max 0.60Max 1.00Max 0.050 0.050 fusionwelded Westermann Tables 5 Specification on Structura1 and Heat treatable Steels General structural steels IS:1977-1969;IS:2062-1969 IS: 226-1969' IS: 961-1962 Designation Tensile Yieldstrength Elongation% C% S% P% ofsteel .rtrength for thicknesses Max Max Max Typicalapplications kgflnun' upto20nun 20-40 mm o5n.6g5a"jfS;ole>nMgthin St32-0 32-44 - - 26 - 0.07 0.07 Intendedforgeneralengineering St42-O 42-54 26.0 - 23 - 0.07 0.07 purposes. St42-5 42-54 26.0 24.0 23 0.25 0.055 0.055 Intendedforalltypesofstructuresweld- ableuponcertainconditions. St42-W 42-54 26.0 24.0 23 0.20 0.055 0.055 Canbesubjectedtofusionwelding. St58-HT 58Min 36.0 35.0 20 0.27 0.055 0.055 Intendedforuseinstructureswhere fabricationisdonebymethodsother o thanwelding. St55-HTW 55Min 36.0 35.0 20 0.20 0.055 0.055 Intendedforuseinstructureswhere weldingisemployedforfabricationand whereguaranteedweldabilityisrequired. Standard sizes ofbot-rolled products made ofgeneral structural lS Number Product Page ISNumber Product Page 808 Beam,channelandanglesections 21 1732 Roundandsquarebars 19 1173 Teebars -22 1863 Bulbplates - 1252 Bulbangles 1864 Unequalangles 21 1730 Plates,sheetandstrip 20 3954 Channelsectionsforgeneralengineeringpurposes 22 1731 Flat. 20 ,2 4 Case hardening IS:4432-1967 ,2 Casehardened Temperalllresfor °C Designation Ten.rilestrength Elongation Carburizing Softening Case Annealing Typicalapplications ofsteel Minkgflmm' %Min hardening CIO,CI4, 19S11 50 17 20 650-680 760-780 - 14MnlSH,IIMn2 60 17 900--930 650-680 760-780 800-920 Thesesteelsareusedforcompo- 15Cr 60 13 900--930 650-680 770--800 870-900 nentsrequiringhighwear 17Mn ICr 80 10 900--930 650-680 810-840 850-880 resistantsurfaces,coupledwith 20MnCr I 100 8 900--930 650-680 810--840 850-880 toughcorestoresistshockIClads 16Ni&!Cr!iQ 70 15 880-920 650-680 780-820 850-880 andstrengthtogivelonger 16Ni ICrJill 85 12 900--930 650-660 780--820 850-880 servicelife. 13Ni3Cr&! 85 12 900-930 620-650 760-780 860-880 .2 15Ni4Cr I 135 9 900--930 600-630 760-780 860-880 20Ni2Mo2.l 85 12 880-920 650-660 760-780 - 20 NilS. CQ!! Mo 2!l 90 II 880-920 650-660 780--820 - 15NiCr IMo.lZ 100 9 900--930 630-650 780-82() 860-880 15Ni2Cr IMol5. 110 9 900--930 630-650 780--820 860-880 16NiCr2 Mo2!l 135 9 900--930 630-650 800--820 850-880 Flame and induction hardening IS: 3930-1966 PropertiesinquenchedandtemperedcO/u/itiolls Hardenillgtemperature Designation Tensilerange 0.2%proof Izodimpact Surface Foroil Forwater Typicalapplications ofsteel kgflmm' stress,Min Min.kgfm hardness quench quench i5 kgf/mm' obtainable i4 HRC C30 60to75 36 5.5 45-50 860--890 860-890 Thesewroughtunalloyedand C45 70to85 44 3.5 55-61 830--860 820--850 alloyedsteelsforflameand T70 70to85 40 2.8 60-63 810-840 78J--810 inductionhardeningareused 37Mn2 60to75 40 4.8 53-59 850-870 840-860 whenhigbcoldstrengthand 40Mn2S.lZ 70to85 46 4.8 53-59 850-870 840--860 goodinlpactpropertiesare 35Mn2Mo 80to95 56 5.5 53-59 840--860 830-850 requited. 50Cr I 80to95 48 2.8 57-62 850--870 840-860 50r:rIV2J. 80to95 48 2.8 57-62 850--870 840--860 4ONi3 80to95 56 5.5 54-60 830--860 840--870 40 Ni2 Cr I Mo 2a 90to 105 66 5.5 54-60 830--840 810-830 31Ni3CrMolS. 90to 105 66 5.5 49-54 850--880 820-840 6 WestermannTables Steeb for hardening mIdtempering IS: 5517-1969 Propertiesinhartkned andtemperedcondition Designation Tensile Yield Normalizing Hardening Quenching Tempering Typical ofsteel strength stressMin, temperatllre temperature medium temperature applications kgflmm' kgJ/mm' .C .C .C C30 60to75 40 860to890 860to890 Wateroroil 550to660 Thesewrought C35Mn']j. 60to75 40 850to880 840to880 Wateroroil 530to760 unalloyedand C40 60to75 38 830to860 830to860 Wateroroil 550to660 alloyedsteelsinthe C45 60to75 38 830to860 830to860 Wateroroil 530to670 fonnofbilletsand C50 80to95 54 810to840 810to840 Oil 550to660 barsforgeneral C55Mn']j. 80to95 54 810to840 810to840 Oil 550to660 engineeringpurposes 4OS.l!i 70to85 48 830to860 830to860 Oil 550to660 areintendedtobe 40Mn2S12 60to75 40 840to870 840to870 Oil 550to660 usedinthehardened 20Mn2 60to75 44 860to900 860to900 Wateroroil 550to660 andtempered 27Mn2 70to85 46 840-to880 840to880 Wateroroil 550to660 condition 35Mn2Mo 100to 115 80 840to860 Oil 550to660 55CrZ!l 90to 105 66 800to850 800to850 Oil 5l'Oto700 40Cr I 80to95 60 850to880 850to880 Oil 550to700 40Cr 1MoZ!i 80to95 60 850to880 850to880 Oil 550to720 40CrAll Mo.l!i 90to 105 70 - 850to900 Oil 550to700 4ONi3 90to105 70 830to860 850to860 Oil 550to650 35Ni 1Cr!2!l 90to 105 70 - 820to850 Wateroroil 550to660 30Ni4Cr I 120to135 DO - 810to830 Airoroil >250 - 40Ni2Cr 1MoZ!i 120to 135 130 830to850 Oil 550to660 31Ni3Cr65Mol5. 120to135 10 - 830to850 Oil upto660 40Ni3Cr65 0 Mol5. 120to135 130 830to850 830to850 Oil upto660 Cold roIledcarbon steel sheets S: 513-1963 Tensile strength C% Mn% S% P% Forall types Typicalapplications Types (for design Max Max Max Max Delivery Surface purpose only) condition finish kgf/mm2 0: Ordinary 28 0.15 - 0.060 0.060 (l) Scale-free Coare Course orroughfor D:Drawing 28 0.12 0.50 0.050 0.050 or rough enamelling and lacquering DD:Deep 28 0.10 0.50 0.040 0.040 (2) Improved Medium Medium ordullfor drawing surface ordull general purposes(not suitableforplating) EDO: Extra 28 0.10 0.50 0.035 0.035 (3) Best Fine or Fine orbrightfor deep drawing surface bright electroplating « Note: Sheetconformingto thisstandard areofweldable quality andare suitableboth for fusionandspotwelding. Hot roUedcarbon steel sheet and strip 1079-1968 Tensile Yield Elongation C% Mn% S% P% Delivery Typical Grade strength stress %Min Max Max Max Max condition applications kgf/mm2 kgf/mm2 0-1079 - - - - - 0.060 0.060 Hot-rolled Used forcold 0-1079 - - -- 0.12 0.50 0.050 0.050 Annealed formed structural - 00-1079 27-40 23 0.10 0.50 0.040 0.040 Normalized members andfor EOO-1079 27-39 - 25 0.10 0.50 0.035 0.035 and other general St 34-1079 34-42 21.0 25 0.15 - 0.050 0.050 Oescaled engineering St 42-1079 42-50 24.0 22 0.25 - 0.050 0.050 purposes St 50-1079 50-60 30.0 20 0.30 - 0.050 0.050 5t 52-10'19 52-62 36.0 20 0.22 - 0.050 0.050