Manufacturing Technology Vol. 1
Published in 2020
Book
Paperback/Softback
464 pages
978-0-19-947548-3 (ISBN)
Description
Manufacturing Technology Vol. 1 is designed for the students of mechanical and allied fields to explain the theory, significance, and applications of various production processes. It provides an overview of various techniques that form an everyday activity in a shop floor.
The book begins with an overview of manufacturing and engineering materials and moves onto discussing processes such as casting, shearing, welding, forming, and moulding. Dedicated chapters on metal forming, metal cutting, and sheet metal forming processes have been provided. An exclusive chapter on forming and shaping of plastics is also presented. It ends with discussion of exclusive chapters on powder metallurgy, additive manufacturing, unconventional manufacturing processes, and glass
manufacturing. Comprehensive in its coverage of various concepts, the book provides neat line sketches, quick recapitulation of essential concepts, review questions, and multiple choice questions (MCQs).
The book begins with an overview of manufacturing and engineering materials and moves onto discussing processes such as casting, shearing, welding, forming, and moulding. Dedicated chapters on metal forming, metal cutting, and sheet metal forming processes have been provided. An exclusive chapter on forming and shaping of plastics is also presented. It ends with discussion of exclusive chapters on powder metallurgy, additive manufacturing, unconventional manufacturing processes, and glass
manufacturing. Comprehensive in its coverage of various concepts, the book provides neat line sketches, quick recapitulation of essential concepts, review questions, and multiple choice questions (MCQs).
More details
Language
English
Place of publication
New Delhi
India
Target group
College/higher education
Illustrations
250 diagrams
Dimensions
Height: 246 mm
Width: 189 mm
ISBN-13
978-0-19-947548-3 (9780199475483)
Copyright in bibliographic data is held by Nielsen Book Services Limited or its licensors: all rights reserved.
Schweitzer Classification
Persons
Dr S. Gowri is Honorary Professor, Dept. of Manufacturing Engineering, College of Engineering Guindy, Anna University, Chennai. After a few years of Industrial experience in Enfield India Limited, he started his academic career in National Institute of Technology, Surathkal, Karnataka. He joined as Professor in Anna University Chennai in 2000 and was sharing responsibilities, in addition to teaching and research, as Project Head in Anna University -
Federal Republic of Germany (AU-FRG) Institute for CAD / CAM.
Dr P. Hariharan is Professor, Dept. of Manufacturing Engineering, College of Engineering Guindy, Anna University, Chennai. His field of specialization is CNC technology, Robotics, CAM, and Cryogenic treatment of materials.
Dr A. Suresh Babu is Associate Professor, Dept. of Manufacturing Engineering, College of Engineering Guindy, Anna University, Chennai. His areas of specialization include composite materials, additive manufacturing, and other manufacturing processes.
Federal Republic of Germany (AU-FRG) Institute for CAD / CAM.
Dr P. Hariharan is Professor, Dept. of Manufacturing Engineering, College of Engineering Guindy, Anna University, Chennai. His field of specialization is CNC technology, Robotics, CAM, and Cryogenic treatment of materials.
Dr A. Suresh Babu is Associate Professor, Dept. of Manufacturing Engineering, College of Engineering Guindy, Anna University, Chennai. His areas of specialization include composite materials, additive manufacturing, and other manufacturing processes.
Author
Honorary Professor, Dept. of Manufacturing EngineeringHonorary Professor, Dept. of Manufacturing Engineering, College of Engineering Guindy
Professor, Dept. of Manufacturing EngineeringProfessor, Dept. of Manufacturing Engineering, College of Engineering Guindy
Associate Professor, Dept. of Manufacturing EngineeringAssociate Professor, Dept. of Manufacturing Engineering, College of Engineering Guindy
Content
Chapter 1 Metal Casting Processes
1.1 Introduction
1.2 Patterns
1.2.1 Pattern materials
1.2.2 Pattern allowances
1.2.3 Types of patterns
1.2.4 Pattern making tools and machines
1.2.5 Wooden pattern making machines
1.3 Moulding Tools, Machines, and Materials
1.3.1 Moulding tools
1.3.2 Moulding sand
1.3.3 Sand properties
1.3.4 Sand preparation
1.3.5 Sand testing methods
1.3.6 Moulding machines
1.4 Core Making
1.4.1 Types of cores
1.4.2 Core print
1.4.3 Core boxes
1.4.4 Core sand preparation
1.4.5 Core moulding
1.4.6 Core baking
1.4.7 Core finishing
1.5 Sand Moulding Methods
1.5.1 Green sand moulding
1.5.2 Dry sand moulding
1.5.3 Skin dried mould
1.5.4 Shell moulding
1.5.5 Investment casting
1.5.6 Carbondioxide (CO2) moulding
1.6 Melting Practice
1.6.1 Melting furnaces
1.6.2 Fluxing
1.6.3 Inoculation
1.6.4 Melting practice of various metals
1.7 Die-casting Processes
1.7.1 Gravity die-casting
1.7.2 Low pressure die-casting
1.7.3 High pressure die-casting
1.7.4 Continuous casting
1.8 Cleaning and Inspection of Casting
1.8.1 Cleaning of casting
1.8.2 Inspection of casting
1.8.3 Casting defects - causes and remedies
1.8.4 Repairing of casting
Chapter 2 Fabrication Processes
2.1 Introduction
2.1.1 Fabrication
2.1.2 Welding
2.1.3 Types of welding
2.1.4 Welding terminology
2.1.5 Weld preparation
2.1.6 Weld symbols
2.2 Arc Welding Processes
2.2.1 Fundamentals of arc welding
2.2.2 Arc welding consumables and equipment
2.2.3 Shielded metal arc welding
2.2.4 Flux cored arc welding
2.2.5 Submerged arc welding (SAW)
2.2.6 Gas metal arc welding (GMAW)
2.2.7 Gas tungsten arc welding (GTAW)
2.2.8 Electro slag welding (ESW)
2.2.9 Electro gas welding (EGW)
2.3 Gas Welding
2.3.1 Principle
2.3.2 Gas welding equipment and supplies
2.3.3 Flame characteristics
2.3.4 Methods and types of gas welding
2.3.5 Flame cutting and hard facing
2.4 Electric Resistance Welding
2.4.1 Basic ideas
2.4.2 Resistance spot welding (RSW)
2.4.3 Resistance seam welding (RSEW)
2.4.4 Resistance projection welding (RPW)
2.4.5 Percussion welding (PEW)
2.4.6 Flash butt welding (FBW)
2.5 Brazing, Soldering, and Adhesive Bonding
2.5.1 Brazing
2.5.2 Soldering
2.5.3 Adhesive bonding
2.6 Special Welding Processes
2.6.1 Plasma arc welding
2.6.2 Electron beam welding
2.6.3 Laser beam welding
2.6.4 Ultrasonic welding
2.6.5 Friction welding
2.6.6 Diffusion welding
2.6.7 Thermit welding
2.7 Welding Defects
2.7.1 Causes and remedies
Chapter 3 Bulk Deformation Processes
3.1 Fundamentals of Metal Forming
3.1.1 Bulk deformation
3.1.2 Sheet metal forming
3.1.3 Hot working and cold working
3.2 Forging
3.2.1 Process characteristics
3.2.2 Forging operations
3.2.3 Forging processes
3.2.4 Forging machines
3.2.5 Forging defects
3.3 Rolling
3.3.1 Process characteristics
3.3.2 Mechanism of rolling
3.3.3 Rolling operations
3.3.4 Types of rolling mills
3.4 Extrusion
3.4.1 Principles
3.4.2 Types
3.4.3 Other extrusion processes
3.4.4 Defects
3.5 Rod Wire and Tube Drawing
3.5.1 Principle
3.5.2 Defects
Chapter 4 Sheet Metal Forming Processes
4.1 Sheet Metal Characteristics
4.1.1 Properties
4.1.2 Suitability of metals
4.2 Cutting Operations
4.2.1 Shearing, Piercing, and Blanking operations
4.2.2 Other sheet metal cutting operations
4.3 Bending
4.3.1 Principles
4.3.2 Types of bending operations
4.3.3 Tube bending
4.4 Deep Drawing
4.4.1 Principles
4.4.2 Types
4.5 High Velocity Forming
4.5.1 Explosive forming
4.5.2 Magnetic pulse forming
4.5.3 Electro-hydraulic forming
4.6 Other Sheet Metal Forming Operations
4.6.1 Squeezing
4.6.2 Stretch forming
4.6.3 Spinning
4.6.4 Peen forming
4.6.5 Superplastic forming
Chapter 5 Forming and Shaping of Plastics (SS Reviewed)
5.1 Types of Plastics
5.1.1 Addition polymerisation
5.1.2 Co-polymerisation and polyaddition
5.1.3 Condensation polymerisation and polycondensation
5.1.4 Thermoplastics
5.1.5 Thermosetting plastics
5.1.6 Elastomers
5.2 Processing of Thermoplastics
5.2.1 Extrusion moulding
5.2.2 Injection moulding
5.2.3 Blow moulding
5.2.4 Rotational moulding
5.2.5 Calendering
5.2.6 Film blowing
5.2.7 Thermoforming
5.3 Processing of Thermoset Plastics
5.3.1 Compression moulding
5.3.2 Transfer moulding
5.3.3 Jet moulding (Injection moulding)
5.3.4 Reinforced plastic
5.3.5 Laminated plastic
5.3.6 Casting
5.4 Bonding of Thermoplastics
5.4.1 Methods
5.4.2 Chemical bonding
5.4.3 Thermal welding
Chapter 6 Additive Manufacturing: An Overview
6.1 Introduction to Additive Manufacturing
6.2 Process Flow of Additive Manufacturing
6.3 Am Materials and Applications
6.4 Applications of Additive Manufacturing
6.5 AM Capabilities and Limitations
6.6 AM Software
6.7 Classification of AM Processes
6.8 Material Extrusion
6.9 Material Jetting
6.10 Binder Jetting
6.11 Sheet Lamination
6.12 Vat Photo Polymerization
6.13 Powder Bed Fusion
6.14 Directed Energy Deposition
6.15 Subtractive Manufacturing vs Additive Manufacturing
Chapter 7 Powder Metallurgy
7.1 Powder Metallurgy: Introduction
7.2 Powder Metallurgy Process
7.3 Mechanical Methods
7.4 Atomization Methods
7.5 Chemical Methods
7.6 Condensation of Metal Powders
7.7 Mixing and Blending of Metallic Powders
7.8 Compaction of Metal Powder
7.9 Sintering
Chapter 8 Surface Coating of Metals
8.1 Introduction
8.2 Thermal Spraying
8.3 Uses of Thermal Spray Coatings
8.4 Vapour Deposition Processes
8.5 Chemical Vapour Deposition Process
8.6 Diffusion Coatings
8.7 Pulsed Laser Deposition
8.8 Electroplating
8.9 Electroless Plating
8.10 Electropolishing
8.11 Anodizing
8.12 Photoetching
8.13 Hardfacing
8.14 Painting
8.15 Mechanical Surface Treatment Process
8.16 Surface Preparation
Chapter 9 Glass and Ceramic Manufacturing
9.1 Introduction
9.2 Types of Glass
9.2 Processing of Glass
9.3 Forming - Glass Shaping Process
9.4 Glass Fibre
9.5 Melting Defects
9.6 Furnaces
9.8 Ceramics
Chapter 10 Unconventional machining processes
10.1 Introduction
10.2 History of Machining
10.3 Classification of Unconventional Machining Processes
10.4 Mechanical Energy Based Processes
10.5 Abrasive Jet Machining
10.6 Water Jet Machining
10.7 Ultrasonic Machining Process
10.7 Abrasive Water Jet Machining
10.9 Thermal Energy-Based Processes
10.10 Electron Beam Machining
10.11 Wire EDM
10.12 Construction
10.13 Chemical Machining Process
10.14 Electrochemical Machining Process
Chapter 11 Metal Cutting
11.1 Introduction
11.2 Types of cutting
11.3 Force components
11.4 Chip formation
11.5 Tool wear and life
11.6 Surface finish and integrity
11.7 Machinability
11.8 Cutting tool materials, fluids, and coating
11.9 Turning, drilling, milling, and finishing
11.10 CNC
1.1 Introduction
1.2 Patterns
1.2.1 Pattern materials
1.2.2 Pattern allowances
1.2.3 Types of patterns
1.2.4 Pattern making tools and machines
1.2.5 Wooden pattern making machines
1.3 Moulding Tools, Machines, and Materials
1.3.1 Moulding tools
1.3.2 Moulding sand
1.3.3 Sand properties
1.3.4 Sand preparation
1.3.5 Sand testing methods
1.3.6 Moulding machines
1.4 Core Making
1.4.1 Types of cores
1.4.2 Core print
1.4.3 Core boxes
1.4.4 Core sand preparation
1.4.5 Core moulding
1.4.6 Core baking
1.4.7 Core finishing
1.5 Sand Moulding Methods
1.5.1 Green sand moulding
1.5.2 Dry sand moulding
1.5.3 Skin dried mould
1.5.4 Shell moulding
1.5.5 Investment casting
1.5.6 Carbondioxide (CO2) moulding
1.6 Melting Practice
1.6.1 Melting furnaces
1.6.2 Fluxing
1.6.3 Inoculation
1.6.4 Melting practice of various metals
1.7 Die-casting Processes
1.7.1 Gravity die-casting
1.7.2 Low pressure die-casting
1.7.3 High pressure die-casting
1.7.4 Continuous casting
1.8 Cleaning and Inspection of Casting
1.8.1 Cleaning of casting
1.8.2 Inspection of casting
1.8.3 Casting defects - causes and remedies
1.8.4 Repairing of casting
Chapter 2 Fabrication Processes
2.1 Introduction
2.1.1 Fabrication
2.1.2 Welding
2.1.3 Types of welding
2.1.4 Welding terminology
2.1.5 Weld preparation
2.1.6 Weld symbols
2.2 Arc Welding Processes
2.2.1 Fundamentals of arc welding
2.2.2 Arc welding consumables and equipment
2.2.3 Shielded metal arc welding
2.2.4 Flux cored arc welding
2.2.5 Submerged arc welding (SAW)
2.2.6 Gas metal arc welding (GMAW)
2.2.7 Gas tungsten arc welding (GTAW)
2.2.8 Electro slag welding (ESW)
2.2.9 Electro gas welding (EGW)
2.3 Gas Welding
2.3.1 Principle
2.3.2 Gas welding equipment and supplies
2.3.3 Flame characteristics
2.3.4 Methods and types of gas welding
2.3.5 Flame cutting and hard facing
2.4 Electric Resistance Welding
2.4.1 Basic ideas
2.4.2 Resistance spot welding (RSW)
2.4.3 Resistance seam welding (RSEW)
2.4.4 Resistance projection welding (RPW)
2.4.5 Percussion welding (PEW)
2.4.6 Flash butt welding (FBW)
2.5 Brazing, Soldering, and Adhesive Bonding
2.5.1 Brazing
2.5.2 Soldering
2.5.3 Adhesive bonding
2.6 Special Welding Processes
2.6.1 Plasma arc welding
2.6.2 Electron beam welding
2.6.3 Laser beam welding
2.6.4 Ultrasonic welding
2.6.5 Friction welding
2.6.6 Diffusion welding
2.6.7 Thermit welding
2.7 Welding Defects
2.7.1 Causes and remedies
Chapter 3 Bulk Deformation Processes
3.1 Fundamentals of Metal Forming
3.1.1 Bulk deformation
3.1.2 Sheet metal forming
3.1.3 Hot working and cold working
3.2 Forging
3.2.1 Process characteristics
3.2.2 Forging operations
3.2.3 Forging processes
3.2.4 Forging machines
3.2.5 Forging defects
3.3 Rolling
3.3.1 Process characteristics
3.3.2 Mechanism of rolling
3.3.3 Rolling operations
3.3.4 Types of rolling mills
3.4 Extrusion
3.4.1 Principles
3.4.2 Types
3.4.3 Other extrusion processes
3.4.4 Defects
3.5 Rod Wire and Tube Drawing
3.5.1 Principle
3.5.2 Defects
Chapter 4 Sheet Metal Forming Processes
4.1 Sheet Metal Characteristics
4.1.1 Properties
4.1.2 Suitability of metals
4.2 Cutting Operations
4.2.1 Shearing, Piercing, and Blanking operations
4.2.2 Other sheet metal cutting operations
4.3 Bending
4.3.1 Principles
4.3.2 Types of bending operations
4.3.3 Tube bending
4.4 Deep Drawing
4.4.1 Principles
4.4.2 Types
4.5 High Velocity Forming
4.5.1 Explosive forming
4.5.2 Magnetic pulse forming
4.5.3 Electro-hydraulic forming
4.6 Other Sheet Metal Forming Operations
4.6.1 Squeezing
4.6.2 Stretch forming
4.6.3 Spinning
4.6.4 Peen forming
4.6.5 Superplastic forming
Chapter 5 Forming and Shaping of Plastics (SS Reviewed)
5.1 Types of Plastics
5.1.1 Addition polymerisation
5.1.2 Co-polymerisation and polyaddition
5.1.3 Condensation polymerisation and polycondensation
5.1.4 Thermoplastics
5.1.5 Thermosetting plastics
5.1.6 Elastomers
5.2 Processing of Thermoplastics
5.2.1 Extrusion moulding
5.2.2 Injection moulding
5.2.3 Blow moulding
5.2.4 Rotational moulding
5.2.5 Calendering
5.2.6 Film blowing
5.2.7 Thermoforming
5.3 Processing of Thermoset Plastics
5.3.1 Compression moulding
5.3.2 Transfer moulding
5.3.3 Jet moulding (Injection moulding)
5.3.4 Reinforced plastic
5.3.5 Laminated plastic
5.3.6 Casting
5.4 Bonding of Thermoplastics
5.4.1 Methods
5.4.2 Chemical bonding
5.4.3 Thermal welding
Chapter 6 Additive Manufacturing: An Overview
6.1 Introduction to Additive Manufacturing
6.2 Process Flow of Additive Manufacturing
6.3 Am Materials and Applications
6.4 Applications of Additive Manufacturing
6.5 AM Capabilities and Limitations
6.6 AM Software
6.7 Classification of AM Processes
6.8 Material Extrusion
6.9 Material Jetting
6.10 Binder Jetting
6.11 Sheet Lamination
6.12 Vat Photo Polymerization
6.13 Powder Bed Fusion
6.14 Directed Energy Deposition
6.15 Subtractive Manufacturing vs Additive Manufacturing
Chapter 7 Powder Metallurgy
7.1 Powder Metallurgy: Introduction
7.2 Powder Metallurgy Process
7.3 Mechanical Methods
7.4 Atomization Methods
7.5 Chemical Methods
7.6 Condensation of Metal Powders
7.7 Mixing and Blending of Metallic Powders
7.8 Compaction of Metal Powder
7.9 Sintering
Chapter 8 Surface Coating of Metals
8.1 Introduction
8.2 Thermal Spraying
8.3 Uses of Thermal Spray Coatings
8.4 Vapour Deposition Processes
8.5 Chemical Vapour Deposition Process
8.6 Diffusion Coatings
8.7 Pulsed Laser Deposition
8.8 Electroplating
8.9 Electroless Plating
8.10 Electropolishing
8.11 Anodizing
8.12 Photoetching
8.13 Hardfacing
8.14 Painting
8.15 Mechanical Surface Treatment Process
8.16 Surface Preparation
Chapter 9 Glass and Ceramic Manufacturing
9.1 Introduction
9.2 Types of Glass
9.2 Processing of Glass
9.3 Forming - Glass Shaping Process
9.4 Glass Fibre
9.5 Melting Defects
9.6 Furnaces
9.8 Ceramics
Chapter 10 Unconventional machining processes
10.1 Introduction
10.2 History of Machining
10.3 Classification of Unconventional Machining Processes
10.4 Mechanical Energy Based Processes
10.5 Abrasive Jet Machining
10.6 Water Jet Machining
10.7 Ultrasonic Machining Process
10.7 Abrasive Water Jet Machining
10.9 Thermal Energy-Based Processes
10.10 Electron Beam Machining
10.11 Wire EDM
10.12 Construction
10.13 Chemical Machining Process
10.14 Electrochemical Machining Process
Chapter 11 Metal Cutting
11.1 Introduction
11.2 Types of cutting
11.3 Force components
11.4 Chip formation
11.5 Tool wear and life
11.6 Surface finish and integrity
11.7 Machinability
11.8 Cutting tool materials, fluids, and coating
11.9 Turning, drilling, milling, and finishing
11.10 CNC