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Manufacturing Technology - I
For 3rd Semester B.E. Mechanical Engineering
As per the Latest Syllabus of ANNA UNIVERSITY, CHENNAI

Dr. G.K. VIJAYARAGHAVAN, B.E., M.Tech., Ph.D.

Adviser,
Dhaanish Ahmed College of Engineering,
Padappai, Chennai, Tamilnadu.
E-mail: haigkv@yahoo.com
Website: wwww. gkvbooks.comm

Dr. R. RAJAPPAN, B.E., M.E., Ph.D.

Professor & Dean,
Mailam Engineering College,
Mailam, Tindivanam (TK), Tamilnadu.

LAKSHMI PUBLICATIONS
Plot No.73, Gokula Nagar, 2nd Main Road (40 Feet Road),
Perumbakkam, Medavakkam (P.O),
Chennai – 600 100, Tamil Nadu, INDIA.
Phone: 044 - 49523977, 98945 98598, 96772 21371.
E-mail: lakshmipublication@gmail.com, suchitrapublications@gmail.com
Manufacturing Technology - I
by Dr. G.K. Vijayaraghavan and Dr. R. Rajappan

First Edition: May 2018

© All rights are exclusively reserved by the author(s)

No part of this publication can be reproduced, stored in a retrieval system or transmitted in any
form or by any means, mechanical, photocopying, recording or otherwise, without the prior
written permission of the author.

Price: Rs. 300/-

ISBN:

Published by and copies can be had from:

LAKSHMI PUBLICATIONS
Plot No.73, VGP Gokul Nagar,
2nd Main Road (40 Feet Road),
Perumbakkam, Medavakkam P.O,
Chennai - 600 100, Tamil Nadu, INDIA.
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 Dedicated to
My
Beloved Students
 PREFACE

I am pleased to bring out the first edition of “Manufacturing Technology - I”

book for Engineering and Technology studies. This book is written to serve the needs
of undergraduate students embarking introductory course in Manufacturing
Technology. This book is based on the latest syllabi prescribed by the Anna
University Chennai, Trichy, Coimbatore & Tirunelveli for 3rd Semester Mechanical
engineering students of its affiliated colleges.
This book consists of 5 units.

 Unit 1 deals with the sand casting, sand mould, type of patterns, pattern
materials, pattern allowances, moulding sand properties and testing, types
and applications cores, types and applications of moulding machines, various
melting furnaces such as blast and cupola furnaces, principle of special
casting processes such as shell, investment, ceramic mould, pressure die
casting, centrifugal casting, CO2 process, stir casting and defects in sand
castings.

 Unit 2 describes in detail about Operating principle, basic equipment, merits

and applications of various joining processes such as gas welding, manual
metal arc welding, gas tungsten arc welding, gas metal arc welding,
submerged arc welding, electro slag welding, resistance welding, plasma arc
welding, thermit welding, electron beam welding, friction welding and
friction stir welding, brazing and soldering. This unit also deals with types,
causes and cure of weld defects.

 Unit 3 has an in-depth dealing of various metal forming processes such as

hot working and cold working of metals, open, impression and closed die
forging processes with forging operations, rolling of metals, flat strip rolling,
shape rolling operations, defects in rolled parts, rod and wire drawing, tube
drawing, hot and cold extrusion.

 Unit 4 elaborately discusses various sheet metal topics such as sheet metal
characteristics, shearing, bending and drawing operations, stretch forming
operations, formability of sheet metal, test methods, special forming
 processes, working principle and applications, hydro forming, rubber pad
forming, metal spinning, introduction of explosive forming, magnetic pulse
forming, peen forming, superplastic forming and micro forming

 Unit 5 deals with the manufacturing of plastic components in which various

topics such as types and characteristics of plastics, moulding of
thermoplastics, working principles and typical applications of injection
moulding, plunger and screw machines, compression moulding, transfer
moulding, introduction to blow moulding, rotational moulding, film blowing,
extrusion, thermoforming and bonding of thermoplastics.

Important solved University questions, and two mark questions and answers have
been added at the tail end of each unit which will enable the students to score high
marks in the University examinations. Recent Solved Anna University Question
Papers have been added at the end of this book.

With these features, I sincerely hope that this book would serve as a valuable text
for the students.
Though efforts have been taken aiming at a ‘zero flaw’ content, I do recognize
that mistakes may have inadvertently crept in. I welcome constructive criticisms on
any specific topics of this book.

My sincere thanks to Mrs. Nirmala Durai, Proprietor of “Lakshmi

Publications” and Publishing Advisor Mr. A. DURAI, B.E. for their involvement to
make this publication successful.

- Dr. G.K. VIJAYARAGHAVAN

 ME8352 MANUFACTURING TECHNOLOGY - I

UNIT I METAL CASTING PROCESSES

Sand Casting : Sand Mould – Type of patterns - Pattern Materials – Pattern allowances –
Moulding sand Properties and testing – Cores –Types and applications – Moulding
machines – Types and applications; Melting furnaces : Blast and Cupola Furnaces;
Principle of special casting processes : Shell - investment – Ceramic mould – Pressure
die casting - Centrifugal Casting - CO2 process – Stir casting; Defects in Sand casting.

UNIT II JOINING PROCESSES

Operating principle, basic equipment, merits and applications of: Fusion welding
processes : Gas welding - Types – Flame characteristics; Manual metal arc welding –
Gas Tungsten arc welding - Gas metal arc welding – Submerged arc welding – Electro
slag welding; Operating principle and applications of : Resistance welding - Plasma arc
welding – Thermit welding – Electron beam welding – Friction welding and Friction Stir
Welding; Brazing and soldering; Weld defects: types, causes and cure.

UNIT III METAL FORMING PROCESSES

Hot working and cold working of metals – Forging processes – Open, impression and
closed die forging – forging operations. Rolling of metals– Types of Rolling – Flat strip
rolling – shape rolling operations – Defects in rolled parts. Principle of rod and wire
drawing – Tube drawing – Principles of Extrusion – Types – Hot and Cold extrusion.

UNIT IV SHEET METAL PROCESSES

Sheet metal characteristics – shearing, bending and drawing operations – Stretch forming
operations – Formability of sheet metal – Test methods –special forming processes-
Working principle and applications – Hydro forming – Rubber pad forming – Metal
spinning– Introduction of Explosive forming, magnetic pulse forming, peen forming, Super
plastic forming – Micro forming.

UNIT V MANUFACTURE OF PLASTIC COMPONENTS

Types and characteristics of plastics – Moulding of thermoplastics – working principles
and typical applications – 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.
Contents C-1

UNIT 1 METAL CASTING PROCESSES

1.1 Introduction 1.1

1.2 Sand casting 1.1
1.3 Sand mould 1.1
1.4 Pattern and pattern making 1.2
1.5 Types of patterns 1.2
1.5.1 Solid pattern or single-piece pattern 1.3
1.5.2 Spilt pattern 1.3
1.5.3 Loose-piece pattern 1.4
1.5.4 Match-plate pattern 1.4
1.5.5 Sweep pattern 1.5
1.5.6 Skeleton pattern 1.5
1.5.7 Segmental pattern 1.6
1.5.8 Shell pattern 1.7
1.6 Pattern materials 1.7
1.6.1 Wood 1.8
1.6.2 Metals 1.9
1.6.3 Plaster 1.10
1.6.4 Plastics 1.10
1.6.5 Wax 1.10
1.7 Pattern allowances 1.10
1.7.1 Shrinking allowance 1.11
1.7.2 Machining or finishing allowance 1.11
1.7.3 Draft of taper allowance 1.12
1.7.4 Distortion or camber allowance 1.13
1.7.5 Rapping or shaking allowance 1.13
1.8 Moulding sand 1.14
1.8.1 Constituents of moulding sand 1.14
C-2 Manufactruing Technology - I

1.8.2 Types of moulding sand 1.18

1.8.3 Properties of moulding sand 1.19
1.8.4 Moulding sand preparation 1.21
1.8.5 Moulding tools 1.22
1.8.6 Testing of moulding sand 1.26
1.8.7 Solved problems on moulding sand properties 1.36
1.9 Cores 1.38
1.9.1 Essential qualities of a core 1.39
1.9.2 Core making materials 1.39
1.9.3 Core sand preparation 1.40
1.9.4 Core binders 1.40
1.9.5 Core boxes 1.41
1.9.6 Core ovens 1.43
1.9.7 Core making methods 1.45
1.9.8 Types of cores 1.49
1.9.9 Various methods of testing core sand 1.52
1.10 Moulding processes 1.53
1.10.1 Types of mould 1.53
1.11 Moulding methods 1.57
1.11.1 Bench moulding 1.57
1.11.2 Floor moulding 1.58
1.11.3 Pit moulding 1.58
1.11.4 Sweep moulding 1.58
1.11.5 Plate moulding 1.59
1.12 Moulding machines 1.60
1.12.1 Jolting machine 1.60
1.12.2 Squeezing machine 1.61
1.12.3 Bottom squeezer machine 1.61
1.12.4 Sand slinger 1.61
1.13 Melting furnaces 1.62
Contents C-3

1.13.1 Blast furnace 1.63

1.13.2 Cupola furnace 1.64
1.13.3 Crucible furnace 1.67
1.13.4 Electric furnaces 1.69
1.14 Principle of Special casting processes 1.73
1.14.1 Shell mould casting 1.73
1.14.2 Investment casting 1.75
1.14.3 Ceramic mould casting 1.79
1.14.4 Pressure die casting 1.79
1.14.5 Gravity die casting 1.82
1.14.6 Centrifugal casting 1.83
1.14.7 Continuous casting process 1.84
1.14.8 Carbon Dioxide (CO2) process 1.86
1.14.9 Stir casting 1.88
1.15. Difficulties involved in casting steels over cast irons 1.89
1.16. Cleaning of castings 1.89
1.17. Comparison of casting processes 1.91
1.18 Defects in castings 1.93
1.19 Two mark questions and answers 1.98
1.20 Solved questions 1.114

UNIT 2 JOINING PROCESSES

2.1 Introduction to welding 2.1

2.1.1 Advantages of welded joints 2.2
2.1.2 Disadvantages of welded joints 2.2
2.2 Classification of welding process based on method of welding 2.3
2.2.1 Fusion welding 2.4
2.2.2 Plastic welding 2.4
C-4 Manufactruing Technology - I

2.3. Classification of welding process based on filler metals 2.4

2.4 Gas welding 2.5
2.4.1 Oxy-Acetylene welding 2.5
2.4.2 Air-Acetylene welding 2.6
2.4.3 Oxy- Hydrogen welding 2.6
2.4.4 Gas welding equipment 2.6
2.4.5 Types of flames 2.9
2.4.6 Gas welding techniques 2.11
2.4.7 Filler rods for gas welding 2.12
2.4.8 Advantages, limitations and applications of gas welding 2.13
2.5 Manual metal arc welding (MMAW) or shielded metal arc welding 2.13
2.5.1 Manual metal arc welding equipment 2.14
2.5.2 Comparison of AC and DC welding machines 2.16
2.5.3 Electrodes and its types 2.17
2.5.4 Advantages, limitations and applications of MMAW 2.19
2.5.5 Comparison of arc welding and gas welding 2.20
2.6. Gas Tungsten Arc Welding (GTAW) 2.21
2.6.1 Advantages, limitations and applications of TIG welding 2.23
2.7 Gas Metal Arc Welding (GMAW) 2.24
2.7.1 Difference between TIG and MIG welding 2.27
2.7.2 Advantages, limitations and applications of MIG welding 2.28
2.8 Submerged Arc Welding (SAW) 2.29
2.8.1 Advantages, limitations and applications of SAW 2.30
2.9 Electro Slag Welding (ESW) 2.31
2.9.1 Advantages, limitations and applications of ESW 2.33
2.10 Resistance welding 2.33
2.10.1 Principle of resistance welding 2.34
2.10.2 Parameters influencing in resistance welding 2.35
2.10.3 Advantages, limitations and applications of resistance welding 2.36
2.10.4 Resistance spot welding 2.37
Contents C-5

2.10.5 Resistance Seam Welding (RSW) 2.39

2.10.6 Projection welding 2.40
2.10.7 Resistance butt welding 2.41
2.10.8 Percussion welding 2.43
2.10.9 Resistance stud welding 2.45
2.11 Plasma arc welding 2.46
2.11.1 Types of plasma arc welding 2.46
2.11.2 Advantages, limitations and applications of plasma arc welding 2.49
2.12 Thermit welding 2.50
2.12.1 Classification of Thermit welding 2.51
2.12.2 Operation of Thermit welding 2.51
2.13 Electron Beam Welding (EBW) 2.54
2.13.1 Working principle 2.54
2.13.2 Advantages, limitations and applications of EBW 2.56
2.14 Laser Beam Welding (LBW) 2.57
2.14.1 Working principle 2.58
2.14.2 Primary types of lasers used in welding 2.59
2.14.3 Advantages, limitations and applications of LBW 2.59
2.15 Friction welding 2.60
2.15.1 Sequence of operation in friction welding 2.62
2.15.2 Types of friction welding 2.63
2.15.3 Advantages, limitations and applications of friction welding 2.63
2.16 Friction stir welding 2.64
2.16.1 Advantages, limitations and applications of
friction stir welding 2.65
2.17 Ultrasonic welding 2.67
2.17.1 Ultrasonic welding equipment 2.67
2.17.2 Advantages, limitations and applications of
ultrasonic welding 2.69
2.18 Welding positions 2.71
C-6 Manufactruing Technology - I

2.19 Brazing 2.72

2.19.1 Brazing methods 2.73
2.19.2 Filler materials and fluxes in brazing 2.74
2.20 Soldering 2.75
2.20.1 Typical solders and their applications 2.77
2.20.2 Effects of various alloying elements in soldering 2.77
2.20.3 Soldering methods 2.78
2.20.4 Difference between soldering and brazing 2.79
2.21 Defects in welding 2.80
2.22 Nondestructive testing of weldment 2.86
2.22.1 Visual inspection 2.86
2.22.2 Magnetic particle inspection 2.87
2.22.3 Dye-penetrant inspection or liquid penetrant inspection 2.88
2.22.4 Radiographic inspection 2.89
2.22.5 Ultrasonic inspection 2.90
2.23 Two mark questions and answers 2.92
2.24 Solved questions 2.118

UNIT 3 METAL FORMING PROCESSES

3.1 Introduction 3.1

3.2 Hot working and cold working of metals 3.2
3.2.1 Principle of hot working 3.2
3.2.1.1 Hot working operations 3.3
3.2.1.2 Advantages and disadvantages of hot working process 3.3
3.2.2 Principle of cold working 3.4
3.2.2.1 Cold working operations 3.4
3.2.2.2 Advantages and disadvantages of cold working process 3.5
3.2.3 Comparison between hot working and cold working 3.5
3.3 Forging processes 3.6
Contents C-7

3.3.1 Steps in forging operation 3.6

3.3.2 Classification of forging operations 3.7
3.3.3 Open die forging 3.7
3.3.4 Impression die forging 3.8
3.3.5 Closed die forging 3.9
3.3.6 Characteristics of open die and closed die processes 3.10
3.3.7 Difference between open die and closed die forging processes 3.11
3.3.8 Drop forging 3.12
3.3.9 Press forging 3.12
3.3.10 Comparison between press forging and drop forging 3.14
3.3.11 Upset forging 3.14
3.3.12 Roll forging 3.15
3.3.13 Precision forging 3.16
3.3.14 Seamless rolled ring forging 3.16
3.3.15 Forging tools 3.17
3.4 Forging hammers 3.22
3.4.1 Gravity drop hammers 3.23
3.4.2 Power hammers 3.23
3.4.3 Vertical counterblow hammers 3.24
3.4.4 Horizontal counterblow hammers 3.24
3.5 Power presses 3.25
3.5.1 Screw press 3.25
3.5.2 Hydraulic press 3.25
3.5.3 Mechanical presses 3.26
3.5.4 Difference between forging hammers and forging presses 3.28
3.6 Typical forging operations 3.28
3.6.1 Upsetting 3.28
3.6.2 Drawing down 3.29
3.6.3 Fullering 3.30
3.6.4 Punching and drifting 3.31
C-8 Manufactruing Technology - I

3.6.5 Piercing 3.31

3.6.6 Bending 3.32
3.6.7 Swaging 3.32
3.6.8 Edging 3.33
3.6.9 Flattering and setting down 3.34
3.6.10 Cutting 3.34
3.6.11 Trimming 3.34
3.6.12 Coining 3.35
3.6.13 Forge welding 3.35
3.7 Comparison of forged components with cast components 3.36
3.8 Forging defects 3.37
3.9 Advantages and disadvantages of forging process 3.38
3.10 Rolling of metals 3.39
3.10.1 Types of rolling 3.40
3.10.1.1 Hot rolling 3.40
3.10.1.2 Cold rolling 3.40
3.11 Types of rolling mills 3.41
3.11.1 Two-high rolling mill 3.42
3.11.2 Three-high rolling mill 3.42
3.11.3 Four-high rolling mill 3.43
3.11.4 Multiple or cluster rolling mill 3.43
3.11.5 Tandem rolling mill 3.44
3.11.6 Universal rolling mill 3.44
3.11.7 Planetary rolling mill 3.44
3.12 Flat strip rolling 3.45
3.12.1 Analysis of flat rolling 3.46
3.12.2 Roll bite condition 3.48
3.12.3 Maximum reduction per pass 3.49
3.12.4 Roll force, torque, and power requirements 3.50
3.12.5 Solved problems on flat rolling process 3.53
Contents C-9

3.13 Shape rolling operations 3.56

3.13.1 Ring rolling 3.57
3.13.2 Thread rolling 3.58
3.13.3 Tube piercing or roll piercing 3.60
3.14 Defects in rolled parts 3.61
3.15 Principle of drawing 3.64
3.16 Classification of drawing 3.64
3.16.1 Wire drawing 3.64
3.16.2 Rod drawing 3.65
3.16.3 Rod and wire drawing process 3.66
3.16.4 Difference between wire drawing and rod drawing 3.67
3.16.5 Tube drawing 3.67
3.16.6 Difference between wire drawing and tube drawing 3.70
3.16.7 Deep drawing or sheet drawing 3.70
3.16.8 Features of a drawing die 3.72
3.17 Equipment used in drawing 3.73
3.17.1 Draw bench 3.73
3.17.2 Bull block 3.74
3.18 Principle of extrusion 3.74
3.19 Types of extrusion 3.75
3.19.1 Hot extrusion 3.75
3.19.1.1 Forward or direct extrusion 3.76
3.19.1.2 Indirect or backward extrusion 3.77
3.19.2 Impact extrusion or cold extrusion 3.78
3.19.3 Tube extrusion 3.79
3.20 Hydrostatic extrusion 3.80
3.21 Two mark questions and answers 3.82
3.22 Solved questions 3.103
C-10 Manufactruing Technology - I

UNIT 4 SHEET METAL PROCESSES

4.1 Introduction 4.1

4.1.1 Classification of sheet metal operations 4.2
4.2 Characteristics or properties of sheet metals 4.3
4.3 Shearing process 4.5
4.3.1 Phases in shearing 4.6
4.4 Sheet metal operations 4.7
4.4.1 Shearing or cutting operations 4.7
4.4.2 Forming operations 4.11
4.5 Shearing dies 4.13
4.5.1 Simple dies 4.14
4.5.2 Progressive dies 4.14
4.5.3 Compound dies 4.15
4.5.4 Combination dies 4.17
4.6 Clearance 4.18
4.6.1 Clearance for blanking 4.19
4.6.2 Clearance for piercing or punching 4.19
4.6.3 Effect of clearance 4.20
4.6.4 Force required for punching 4.20
4.6.5 Smallest hole that can be punched 4.20
4.6.6 Solved problems on punching 4.21
4.7 Bending process 4.22
4.7.1 Bending operations 4.23
4.7.2 Springback in bending 4.28
4.8 Drawing process 4.28
4.8.1 Factors affecting drawing 4.30
4.8.2 Blank holding pressure 4.30
4.9 Redrawing 4.30
Contents C-11

4.9.1 Direct redrawing 4.30

4.9.2 Indirect redrawing or reverse drawing 4.31
4.9.3 Ironing 4.32
4.10 Difference between bending, forming and drawing 4.33
4.11 Stretch forming operations 4.33
4.11.1 Methods of stretch forming 4.33
4.12 Formability of sheet metal 4.36
4.13 Formability test methods 4.37
4.13.1 Formability tests for bulk deformation 4.37
4.13.2 Formability tests for elastic-plastic deformation 4.38
4.13.3 Forming limit diagram (FLD) 4.40
4.14 Special forming processes 4.42
4.14.1 Hydroforming process 4.42
4.14.2 Rubber pad forming process 4.44
4.14.3 Rubber hydroforming process 4.46
4.14.4 Metal spinning process 4.47
4.14.5 Explosive forming process 4.49
4.14.6 Magnetic pulse forming process 4.52
4.14.7 Peen forming process 4.54
4.14.8 Superplastic forming process 4.55
4.14.9 Micro forming in sheet metal processes 4.57
4.15 Characteristics of sheet metal forming processes 4.58
4.16 Presses for sheet metal working 4.59
4.16.1 Types of press working 4.60
4.16.2 Types of presses 4.60
4.16.3 Fly press 4.61
4.16.4 Power presses 4.61
4.16.5 Single, double and triple-action presses 4.61
4.16.6 Selection of presses for sheet metal 4.62
4.17 Two mark questions and answers 4.63
4.18 Solved questions 4.85
C-12 Manufactruing Technology - I

UNIT 5 MANUFACTURE OF PLASTIC COMPONENTS

5.1 Introduction 5.1

5.1.1. Polymers 5.2
5.1.2. Polymerization process 5.2
5.1.3. Materials used for processing of plastics 5.3
5.1.4. Characteristics of plastics 5.4
5.2. Types of plastics 5.5
5.2.1. Thermosetting plastics 5.5
5.2.2. Thermoplastics 5.7
5.2.3. Difference between thermoplastics and thermosetting plastics 5.9
5.3. Moulding of thermoplastics and applications 5.10
5.3.1. Injection moulding 5.10
5.3.1.1. Ram or plunger type injection moulding 5.11
5.3.1.2. Screw type injection moulding 5.12
5.3.1.3. Defects in plastic injection moulding 5.13
5.3.2. Blow moulding 5.18
5.3.3. Injection blow moulding process 5.19
5.3.4. Extrusion blow moulding process 5.21
5.3.5. Difference between injection moulding and blow moulding 5.22
5.3.6. Rotational moulding 5.22
5.3.7. Film blowing 5.24
5.3.8. Sheet making 5.25
5.3.9. Extrusion process 5.26
5.3.10. Thermoforming 5.27
5.4. Processing of thermosetting plastics 5.30
5.4.1. Compression moulding 5.30
5.4.2. Transfer moulding 5.32
5.5. Characteristics of various plastic manufacturing processes 5.33
 Contents C-13

5.6. Plastic lamination process 5.34

5.7. Bonding of thermoplastics 5.36
5.7.1. Adhesive and solvent bonding methods 5.37
5.7.1.1. Solvent bonding 5.37
5.7.1.2. Adhesive bonding 5.38
5.7.2. Welding or fusion bonding methods 5.40
5.7.2.1. Friction bonding or friction welding 5.41
5.7.2.2. Ultrasonic welding or ultrasonic bonding 5.42
5.7.2.3. Vibration welding or vibration bonding 5.43
5.7.2.4. Induction welding or induction bonding 5.44
5.7.2.5. Hot gas welding 5.45
5.7.2.6. Hot tool welding 5.47
5.8. Two mark questions and answers 5.48
5.9. Solved questions 5.66

Solved Anna University Question Papers Q-1

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