1．Introduction 1
1.1 Manufacturing Processes 2
1.2 Breakeven Analysis 3
References 8
Questions 8
Problems 8
part A ENGINEERING MATERIALS AND THEIR PROPERTIES 8
2．Engineering Properties and Their Measurement 13
2.1 Strength 13
2.2 Hardness 14
2.3 Ductility 18
2.4 Toughness 19
References 20
Indian Standards 20
Questions 21
3．Ferrous Materials 22
3.1 Iron 23
3.2 Structure of Materials 23
3.3 Plain Carbon Steels 27
3.4 Iron Carbon Equilibrium Diagram 29
3.5 Cast Irons 31
3.6 Other Alloying Elements 32
3.7 Steel Designation 35
References 37
Indian Standards 38
Questions 38
4．Non-Ferrous Materials 40
4.1 Aluminium 40
4.2 Copper 41
4.3 Other Materials 42
References 43
Indian Standards 43
Questions 44
5．Heat Treatment of Metals 45
5.1 Transformation Curves 45
5.2 Hardening 47
5.3 Tempering 50
5.4 Annealing and Normalising 52
5.5 Case Hardening 53
5.6 Heat Treatment of Non-Ferrous Alloys 55
References 56
Indian Standards 56
Questions 56
part B METAL CASTING PROCESSES 56
6．Metal Casting Processes 61
6.1 History 61
6.2 Advantages and Limitations 62
6.3 Applications 62
6.4 Casting Terms 62
6.5 Sand Mould Making Procedure 64
References 65
Indian Standards 65
Questions 65
7．Patterns 67
7.1 Pattern Allowances 67
7.2 Core Prints 73
7.3 Elimination of Details 73
7.4 Pattern Materials 74
7.5 Types of Patterns 76
7.6 Pattern Colour Code 80
References 80
Indian Standards 80
Questions 81
Problems 81
8．Moulding Materials 88
8.1 Moulding Sand Composition 89
8.2 Testing Sand Properties 91
8.3 Sand Preparation 96
8.4 Moulding Sand Properties 97
8.5 Indian Sands 102
8.6 Other Sands 104
8.7 Fluidity 107
8.8 Types of Sand Moulds 109
8.9 Moulding Machines 111
References 112
Indian Standards 112
Questions 113
Problems 114
9．Cores 115
9.1 Core Sands 116
9.2 Carbon Dioxide Moulding 116
9.3 Types of Cores 117
9.4 Core Prints 119
9.5 Chaplets 122
9.6 Forces Acting on the Moulding Flasks 123
References 124
Indian Standards 124
Questions 125
Problems 125
10．Elements of Gating Systems 126
10.1 Elements of a Gating System 127
10.2 Gates 129
10.3 Casting Yield 132
References 133
Questions 134
11．Gating System Design 135
11.1 Pouring Time 136
11.2 Choke Area 138
11.3 Sprue 141
11.4 Other Gating Elements 142
11.5 Gating Ratios 144
11.6 Slag Trap Systems 148
References 151
Questions 152
Problems 152
12．Risering Design 156
12.1 Caine's Method 157
12.2 Modulus Method 159
12.3 Naval Research Laboratory Method 163
12.4 Feeding Distances 170
12.5 Chills 170
12.6 Feeding Aids 174
References 179
Indian Standards 180
Questions 180
Problems 180
13．Melting Practice 182
13.1 Cupola 182
13.2 Charge Calculations 185
13.3 Other Furnaces 188
13.4 Ladles 189
References 190
Indian Standards 191
Questions 191
Problems 191
14．Casting Cleaning and Casting Defects 194
14.1 Fettling 195
14.2 Defects in Castings 195
References 198
Questions 198
15．Product Design for Sand Castings 200
15.1 Designing for Economical Moulding 200
15.2 Designing for Eliminating Defects 203
15.3 Features to Aid Handling 210
References 211
Questions 211
16．Special Casting Processes 214
16.1 Shell Moulding 214
16.2 Precision Investment Casting 217
16.3 Permanent Mould Casting 219
16.4 Die Casting 220
16.5 Centrifugal Casting 225
16.6 Continuous Casting 227
References 227
Indian Standards 230
Questions 230
part C METAL FORMING PROCESSES 230
17．Metal Forming Processes 233
17.1 Nature of Plastic Deformation 233
17.2 Hot Working and Cold Working 234
References 238
Questions 239
18．Rolling 240
18.1 Principle 240
18.2 Rolling Stand Arrangement 242
18.3 Rolling Load 244
18.4 RollPasses 245
18.5 Breakdown Passes 246
18.6 Roll Pass Sequences 248
References 250
Indian Standards 253
Questions 253
19．Forging 254
19.1 Forging Operations 254
19.2 Smith Forging 255
19.3 Drop Forging 255
19.4 Press Forging 257
19.5 Machine Forging 257
19.6 Forging Defects 258
19.7 Forging Design 259
19.8 Drop Forging Die Design 265
19.9 Upset Forging Die Design 272
References 280
Indian Standards 281
Questions 281
20．Extrusion and Other Processes 284
20.1 Extrusion Principle 284
20.2 Hot Extrusion Processes 286
20.3 Cold Extrusion 287
20.4 Tooling for Cold Extrusion 289
20.5 Extruding Tubes 290
20.6 Wire Drawing 292
20.7 Rod and Tube Drawing 294
20.8 Swaging 295
20.9 Tube Making 296
References 297
Questions 298
21．Sheet Metal Operations 299
21.1 Press Tool Operations 299
21.2 Shearing Action 300
21.3 Shearing Operations 303
21.4 Drawing 309
21.5 Draw Die Design 311
21.6 Spinning 317
21.7 Bending 317
21.8 Stretch Forming 321
21.9 Embossing and Coining 322
References 323
Questions 323
Problems 324
22．Sheet Metal Die Design 327
22.1 Types of Dies 327
22.2 Die Construction 329
22.3 Punch Design 333
22.4 Pilots 340
22.5 Stripper and Stock Guide 342
22.6 Die Stops 344
22.7 Stock Strip Layout 346
22.8 Component Design for Blanking 349
22.9 Strip Development 350
22.10 Centre Line of Pressure 354
References 355
Indian Standards 355
Questions 356
part D METAL FABRICATION PROCESSES 356
23．Introduction to Fabrication Processes 361
23.1 Classification 361
23.2 General Considerations 362
References 366
Indian Standards 366
Questions 366
24．Gas Welding and Cutting 368
24.1 Principle 368
24.2 Oxy-Acetylene Welding Equipment 370
24.3 Oxy-Acetylene Welding Technique 371
24.4 Oxy-Hydrogen Welding 373
24.5 Gas Cutting 374
References 377
Indian Standards 377
Questions 378
25．Electric Arc Welding 379
25.1 Principle of Arc 379
25.2 Arc Welding Equipment 380
25.3 Electrodes 382
25.4 Manual Metal Arc Welding 384
25.5 Carbon Arc Welding 392
25.6 Inert Gas Shielded Arc Welding 393
25.7 Tungsten Inert Gas Welding（TIG） 394
25.8 Gas Metal Arc.Welding（GMAW） 398
25.9 Submerged Arc Welding（SAW） 407
25.10 Other Arc Welding Processes 412
25.11 Arc Cutting 415
References 415
Indian Standards 416
Questions 417
26．Resistance Welding 419
26.1 Principle 419
26.2 Resistance Spot Welding 422
26.3 Resistance Seam Welding 425
26.4 Projection Welding 425
26.5 Upset Welding 428
26.6 Flash Welding 428
References 428
Indian Standards 429
Questions 429
27．Other Welding Processes 430
27.1 Thermit Welding 430
27.2 Electro Slag Welding 431
27.3 Electron Beam Welding 432
27.4 Laser Beam Welding 434
27.5 Forge Welding 435
27.6 Friction Welding 435
27.7 Diffusion Welding 436
27.8 Explosion Welding 437
References 437
Questions 438
28．Welding Design 439
28.1 Heat Input 439
28.2 Heat Flow 441
28.3 Distortions 446
28.4 Defects in Welding 451
References 454
Questions 454
Problems 454
29．Brazing,Braze Welding and Soldering 456
29.1 Brazing 456
29.2 Braze Welding 457
29.3 Soldering 458
References 459
Indian Standards 459
Questions 459
Appendix SI Units 461
Index 465