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