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MANUFACTURING TECHNOLOGY – I


Semester : 3rd Semester

Branche(s) : Mechanical Engineering

Authors : Dr.G.K. VIJAYARAGHAVAN & Dr.R.RAJAPPAN

Publisher : A.R. Publications

Edition : Eight Edition June 2015

ISBN : 978-81-920486-2-8

Price : Rs. 210 (Prices are subject to change without prior notice)

Syllabus : Click here to download

Contents : Click here to download

We are pleased to bring out our first edition “Manufacturing Technology - I” for Engineering and Technology studies. This book is written to serve the needs of under graduate students embarking introductory course in Manufacturing Technology. This book is designed to meet the requirement of revised syllabus (Regulation 2013) prescribed by the Anna university, Chennai, Trichy, Coimbatore & Tirunelveli effective from June 2014 for 3rd Semester Mechanical Engineering students of its affiliated colleges.
Unit I deals with moulding sand properties, types of moulding sands, moulding procedure, moulding methods, moulding machines, casting processes, casting defects and various inspecting methods of castings.
Unit II has an in depth dealing of arc welding, gas welding and special welding processes. In addition to these, welding defects and types of welded joints are elaborately discussed.
Unit III deals with hot and cold working processes with their typical applications.
Sheet metal characteristics, sheet metal operations, formability tests and special forming processes are elaborately discussed in Unit IV.
Shaping of plastics and moulding of plastics are treated elaborately with their typical applications in Unit V.
Each unit contains two mark questions and answers, review questions. Model question papers are added at the tail end of this book.
With these features, we sincerely hope that this book would serve as a valuable text for the students. Though effects have been taken to ensure ‘zero flaw’ content, we do recognize that mistakes may have inadvertently crept in. We welcome constructive criticism on any specific topics of this book.

MANUFACTURING TECHNOLOGY-1


UNIT I METAL CASTING PROCESSES


Sand casting – Sand moulds - Type of patterns – Pattern materials – Pattern allowances – Types of
Moulding sand – Properties – Core making – Methods of Sand testing – Moulding machines – Types
of moulding machines - Melting furnaces – Working principle of Special casting processes – Shell –
investment casting – Ceramic mould – Lost Wax process – Pressure die casting – Centrifugal casting –
CO2 process – Sand Casting defects.


UNIT II JOINING PROCESSES


Fusion welding processes – Types of Gas welding – Equipments used – Flame characteristics – Filler and Flux materials - Arc welding equipments - Electrodes – Coating and specifications – Principles of Resistance welding – Spot/butt – Seam – Projection welding Percusion welding – GS metal arc welding – Flux cored – Submerged arc welding – Electro slag welding – TIG welding – Principle and application of special welding processes – Plasma arc welding – Thermit welding – Electron beam welding – Friction welding – Diffusion welding – Weld defects – Brazing – Soldering process – Methods and process capabilities – Filler materials and fluxes – Types of Adhesive bonding.


UNIT III BULK DEFORMATION PROCESSES


Hot working and cold working of metals – Forging processes – Open impression and closed die forging – Characteristics of the process – Types of Forging Machines – Typical forging operations – Rolling of metals – Types of Rolling mills – Flat strip rolling – Shape rolling operations – Defects in rolled parts – Principle of rod and wire drawing – Tube drawing – Principles of Extrusion – Types of Extrusion – Hot and Cold extrusion – Equipments used.

UNIT IV SHEET METAL PROCESSES




Sheet metal characteristics – Typical shearing operations – Bending – Drawing operations – Stretch forming operations –– Formability of sheet metal – Test methods – Working principle and application of special forming processes – Hydro forming – Rubber pad forming – Metal spinning – Introduction to Explosive forming – Magnetic pulse forming – Peen forming – Super plastic forming.


UNIT V MANUFACTURING OF PLASTIC COMPONENTS


Types of plastics – Characteristics of the forming and shaping processes – Moulding of
Thermoplastics – Working principles and typical applications of – Injection moulding – Plunger and screw machines – Compression moulding – Transfer moulding – Typical industrial applications –Introduction to Blow moulding – Rotational moulding – Film blowing – Extrusion – Thermoforming –Bonding of Thermoplastics.

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