CONTENTS 1. INTRODUCTION 1-10 1.1. Introduction 1 1.2. Classification of Manufacturing Processes 1 1.3. Various Kinds of Production 3 1.4. Computers in Manufacturing 3 1.5. Selection of A Manufacturing Process 4 PROBLEMS 10 2. THE CASTING PROCESS 11-127 2.1. General 11 2.2. Sand-Mould Casting 12 2.3. Patterns 22 2.4. Moulding Materials 31 2.5. Cores 40 2.6. Gates and Risers 47 2.7. Sand Casting Defects 66 2.8. Design of Castings 69 2.9. Miscellaneous Casting Processes 74 2.10. Cleaning and Finishing of Castings 99 2.11. Inspection and Testing of Castings 101 2.12. Repairing and Salvaging Defective Castings 104 2.13. Choice of Casting Method 106 2.14. Comparison of Casting Process with Other Processes 106 2.15. Foundry furnaces 109 2.16. Pouring and Handling equipment 118 PROBLEMS 120 3. Fabrication Processes 128-210 3.1.Welding 128 3.2.Gas Welding 135 3.3.Electric Arc Welding 145 3.4.Resistance Welding 169 3.5.Miscellaneous Welding Processes 175 3.6.Liquid-Solid-State Bonding 184 3.7.Weldability 191 3.8.Testing and Inspection of Welded Joints 193 3.9. Welding Cost 198 3.10. Design Aspects 200 3.11. Hard Facing of Metals 201 3.12. Characteristics of Welding Processes 202 3.13. Adhesive Bonds 203 PROBLEMS 207 4. MECHANICAL WORKING OF METALS 211-319 4.1.General 211 4.2. Rolling 220 4.3.Forging 233 4.4.Extrusion 263 4.5.Pipe and Tube Manufacturing 270 4.6.Drawing of Wire, Rod and Tube 272 4.7.Sheet Metal Working or Press Working of Sheet Metals 276 4.8.Shot Peening 304 4.9 Super-Plastic Forming 305 4.10. HERF 305 4.11. Sheet Metal Formability 311 4.12. Characteristics of Metal Forming Processes 313 PROBLEMS 313 5. PROCESSING OF PLASTICS 320-337 5.1. General 320 5.2. Polymers 320 5.3. Polymerization 320 5.4. Additions to Polymers 321 5.5. Plastics 322 5.6. Processing of Thermoplastic Plastics 324 5.7. Processing of Thermosetting Plastics 327 5.8. Casting of Plastics 328 5.9. Machining of Plastics 329 5.10. Other Processing Methods for Plastics 330 5.11. Welding of Plastics 333 PROBLEMS 335 Appendix : Problems from Competitive Examinations 338-362 Index 363-365