The subject of manufacturing technology is very vast and includes various types of machines tools required to manufacture finished products which range from simple hand-held tools, lathe machines, grinders, milling machines to highly versatile and complicated computerized numerical control or CNC machines and so forth. Of course it also involves several different techniques of manufacturing which can be a subject matter of different details discussion and some of these include casting, forging, alloying, welding, soldering, brazing etc. The primary purpose of the book "Manufacturing Technology" is to provide a reference source that covers most machine tool manufacturing processes. Manufacturing and workshop practices have become an important part in the industrial environment to produce products for the service of mankind. Knowledge of manufacturing practices is highly essential for all machinists familiarizing themselves with modern concepts of manufacturing technologies. The requirement is to provide theoretical and practical knowledge of manufacturing processes and workshop technology to all machinist students. Therefore, an attempt has been made throughout this book to present the knowledge of the respective subject.

Preface ix

1. Metal Casting Processes 1

1. Introduction 1

2. Sand casting 2

3. Sand mould 6

4. Pattern and pattern making 8

5. Types of patterns 9

6. Pattern materials 12

7. Advantage and Disadvantages of Metal Pattern 15

Epilogue 22

References 22

2. Moulding Sand 25

1. Introduction 25

2. mouldings 26

3. Core binders 39

4. Moulding Processes 44

5. Moulding methods 45

6. Moulding Machines 48

Epilogue 50

References 50

3. Principles of Special Casting Processes 52

1. Introduction 52

2. Investment Casting 54

3. Ceramic mould casting 59

4. Pressure die casting 62

5. Gravity die Casting 65

6. Continuous Casting Process 69

7. Comparison of Casting Processes 79

8. Defectsin castings 80

Epilogue 85

References 85

4. Joining Processes 87

1. Introduction 87

2. Gas welding 97

3. Manual Metal arc Welding Equipment 107

4. Comparison of AC and DCwelding machines 109

5. Gas Tungsten Arc Welding (GTAW) 111

6. Gas Metal Arc Welding (GMAW) 113

7. Submerged Arc Welding (SAW) 117

8. Electro Slag Welding (ESW) 119

9. Resistance Welding 120

10. Plasma Arc Welding 121

11. Thermit Welding 122

12. Laser Beam Welding (LBW) 124

13. Friction Welding 125

14. Friction Stir Welding 125

15. Ultrasonic Welding 126

16. Welding Defect 128

Epilogue 130

References 130

5. Metal Forming Processes 132

1. Introduction 132

2. Hot Working and Cold Working of Metals 132

3. Open Die Forging 145

4. Forging Hammers 151

5. Gravity Drop Hammers 152

6. Vertical Counter Blow Hammers 153

7. Power Presses 153

Epilogue 153

References 154

6. Typical Forging Operation (Trimming) Cutting 156

1. Introduction 156

2. Forging Operations 157

3. Cast Components 161

4. Forging Defects 165

Epilogue 166

References 167

7. Rolling of Metals 170

1. Introduction 170

2. Types of Rolling 170

3. Types of Rolling mills 173

4. Flat Strip Rolling 176

5. Shape Rolling Operations 179

Manufacturing Technology

vi

6. Types of Plate Rolling Defects 183

Epilogue 184

References 184

8. Principles of Drawing 187

1. Introduction 187

2. Classification of drawing 187

3. Principle of Extrusion 194

4. Types of Extrusion 194

5. Hot Extrusion 194

6. Friction Extrusion 194

Epilogue 196

References 196

9. Sheet Metal Processes 199

1. Introduction 199

2. Classification of sheet metal operations 199

3. Shearing Process 200

4. Sheet Metal Operations 201

5. Clearance 203

6. Bending process 206

7. Drawing process 211

8. Redrawing 212

9. Stretch Forming Operations 213

10. Special forming processes 215

11. Presses for sheet metal working 219

Epilogue 219

References 220

10. Manufacture of Plastic Components 222

1. Introduction 222

2. Polymerization Process 222

3. Materials used for Processing of Plastics 223

4. Moulding of thermoplastics and applications 225

5. Plunger type injection molding machine 226

6. Induction Welding or Induction Bonding 240

Epilogue 241

References 241

Index 245

Adina Boss pursued her Ph.D. in Manufacturing Systems Engineering from Technological University, Melbourne. She is a Research Associate at Community College, Marburg. Her current research interests are in quality engineering, industrial manufacturing, plant facilities and safety engineering. Boss has contributed several articles and book chapters in the area of engineering and manufacturing.