1.Introduction

1.1 Manufacturing Processes

1.2 Breakeven Analysis

References

Questions

Problems

part A ENGINEERING MATERIALS AND THEIR PROPERTIES

2.Engineering Properties and Their Measurement

2.1 Strength

2.2 Hardness

2.3 Ductility

2.4 Toughness

References

Indian Standards

Questions

3.Ferrous Materials

3.1 Iron

3.2 Structure of Materials

3.3 Plain Carbon Steels

3.4 Iron Carbon Equilibrium Diagram

3.5 Cast Irons

3.6 Other Alloying Elements

3.7 Steel Designation

References

Indian Standards

Questions

4.Non-Ferrous Materials

4.1 Aluminium

4.2 Copper

4.3 Other Materials

References

Indian Standards

Questions

5.Heat Treatment of Metals

5.1 Transformation Curves

5.2 Hardening

5.3 Tempering

5.4 Annealing and Normalising

5.5 Case Hardening

5.6 Heat Treatment of Non-Ferrous Alloys

References

Indian Standards

Questions

part B METAL CASTING PROCESSES

6.Metal Casting Processes

6.1 History

6.2 Advantages and Limitations

6.3 Applications

6.4 Casting Terms

6.5 Sand Mould Making Procedure

References

Indian Standards

Questions

7.Patterns

7.1 Pattern Allowances

7.2 Core Prints

7.3 Elimination of Details

7.4 Pattern Materials

7.5 Types of Patterns

7.6 Pattern Colour Code

References

Indian Standards

Questions

Problems

8.Moulding Materials

8.1 Moulding Sand Composition

8.2 Testing Sand Properties

8.3 Sand Preparation

8.4 Moulding Sand Properties

8.5 Indian Sands

8.6 Other Sands

8.7 Fluidity

8.8 Types of Sand Moulds

8.9 Moulding Machines

References

Indian Standards

Questions

Problems

9.Cores

9.1 Core Sands

9.2 Carbon Dioxide Moulding

9.3 Types of Cores

9.4 Core Prints

9.5 Chaplets

9.6 Forces Acting on the Moulding Flasks

References

Indian Standards

Questions

Problems

10.Elements of Gating Systems

10.1 Elements of a Gating System

10.2 Gates

10.3 Casting Yield

References

Questions

11.Gating System Design

11.1 Pouring Time

11.2 Choke Area

11.3 Sprue

11.4 Other Gating Elements

11.5 Gating Ratios

11.6 Slag Trap Systems

References

Questions

Problems

12.Risering Design

12.1 Caine’s Method

12.2 Modulus Method

12.3 Naval Research Laboratory Method

12.4 Feeding Distances

12.5 Chills

12.6 Feeding Aids

References

Indian Standards

Questions

Problems

13.Melting Practice

13.1 Cupola

13.2 Charge Calculations

13.3 Other Furnaces

13.4 Ladles

References

Indian Standards

Questions

Problems

14.Casting Cleaning and Casting Defects

14.1 Fettling

14.2 Defects in Castings

References

Questions

15.Product Design for Sand Castings

15.1 Designing for Economical Moulding

15.2 Designing for Eliminating Defects

15.3 Features to Aid Handling

References

Questions

16.Special Casting Processes

16.1 Shell Moulding

16.2 Precision Investment Casting

16.3 Permanent Mould Casting

16.4 Die Casting

16.5 Centrifugal Casting

16.6 Continuous Casting

References

Indian Standards

Questions

part C METAL FORMING PROCESSES

17.Metal Forming Processes

17.1 Nature of Plastic Deformation

17.2 Hot Working and Cold Working

References

Questions

18.Rolling

18.1 Principle

18.2 Rolling Stand Arrangement

18.3 Rolling Load

18.4 Roll Passes

18.5 Breakdown Passes

18.6 Roll Pass Sequences

References

Indian Standards

Questions

19.Forging

19.1 Forging Operations

19.2 Smith Forging

19.3 Drop Forging

19.4 Press Forging

19.5 Machine Forging

19.6 Forging Defects

19.7 Forging Design

19.8 Drop Forging Die Design

19.9 Upset Forging Die Design

References

Indian Standards

Questions

20.Extrusion and Other Processes

20.1 Extrusion Principle

20.2 Hot Extrusion Processes

20.3 Cold Extrusion

20.4 Tooling for Cold Extrusion

20.5 Extruding Tubes

20.6 Wire Drawing

20.7 Rod and Tube Drawing

20.8 Swaging

20.9 Tube Making

References

Questions

21.Sheet Metal Operations

21.1 Press Tool Operations

21.2 Shearing Action

21.3 Shearing Operations

21.4 Drawing

21.5 Draw Die Design

21.6 Spinning

21.7 Bending

21.8 Stretch Forming

21.9 Embossing and Coining

References

Questions

Problems

22.Sheet Metal Die Design

22.1 Types of Dies

22.2 Die Construction

22.3 Punch Design

22.4 Pilots

22.5 Stripper and Stock Guide

22.6 Die Stops

22.7 Stock Strip Layout

22.8 Component Design for Blanking

22.9 Strip Development

22.10 Centre Line of Pressure

References

Indian Standards

Questions

part D METAL FABRICATION PROCESSES

23.Introduction to Fabrication Processes

23.1 Classification

23.2 General Considerations

References

Indian Standards

Questions

24.Gas Welding and Cutting

24.1 Principle

24.2 Oxy-Acetylene Welding Equipment

24.3 Oxy-Acetylene Welding Technique

24.4 Oxy-Hydrogen Welding

24.5 Gas Cutting

References

Indian Standards

Questions

25.Electric Arc Welding

25.1 Principle of Arc

25.2 Arc Welding Equipment

25.3 Electrodes

25.4 Manual Metal Arc Welding

25.5 Carbon Arc Welding

25.6 Inert Gas Shielded Arc Welding

25.7 Tungsten Inert Gas Welding （TIG）

25.8 Gas Metal ArcWelding （GMAW）

25.9 Submerged Arc Welding （SAW）

25.10 Other Arc Welding Processes

25.11 Arc Cutting

References

Indian Standards

Questions

26.Resistance Welding

26.1 Principle

26.2 Resistance Spot Welding

26.3 Resistance Seam Welding

26.4 Projection Welding

26.5 Upset Welding

26.6 Flash Welding

References

Indian Standards

Questions

27.Other Welding Processes

27.1 Thermit Welding

27.2 Electro Slag Welding

27.3 Electron Beam Welding

27.4 Laser Beam Welding

27.5 Forge Welding

27.6 Friction Welding

27.7 Diffusion Welding

27.8 Explosion Welding

References

Questions

28.Welding Design

28.1 Heat Input

28.2 Heat Flow

28.3 Distortions

28.4 Defects in Welding

References

Questions

Problems

29.Brazing, Braze Welding and Soldering

29.1 Brazing

29.2 Braze Welding

29.3 Soldering

References

Indian Standards

Questions

Appendix SI Units

Index