Traditional manufacturing relies on specialised equipment and production lines that offer little or no flexibility. Advanced manufacturing entails a variety of production methods that make the most of capital equipment while also being more efficient, effective, and responsive. Although there are some situations where traditional, dedicated methods are still appropriate, such as long, predictable production runs, advanced manufacturing has the ability to accommodate the varying production requirements and mass customization that industry frequently encounters without requiring excessive capital investment. Advanced manufacturing considers all areas of the value chain, from concept to end-of-life concerns, and depends on information and communication technology (ICT) to integrate production and business processes into a streamlined, efficient operation. Advanced manufacturing technologies can be split into three categories: efficient production, intelligent production, and effective organisation.

 This book aims to comprehend the various branches that make up the subject of advanced manufacturing technology, as well as how such concepts are applied in practise. The present piece of work extensively correlates various topics of this field. It talks in detail about casting processes, forming processes, non-destructive testing processes and powder metallurgy. To improve knowledge of the subject matter, a logically oriented discussion was attempted. It also explores plastic injection moulding, process selection and metallic materials. This book is an important source of knowledge because of the cohesive flow of themes, student-friendly language, and extensive use of examples. Because this discipline is rapidly evolving, the contents of this book will assist readers in comprehending the subject's modern concepts and applications.

Preface ix

1. Introduction to Manufacturing 1

1. Introduction 1

2. Design and Manufacturing 1

3. What Does Manufacturing Involve? 8

4. Manufacture from Metals 14

5. Manufacture with Plastics 26

6. Process Planning 28

7. Standardisation and Manufacturing 32

8. Methods of Cost Reduction 34

9. Software in Manufacturing 42

10. Green Manufacturing: ISO 14000 43

Conclusion 50

References 50

MCQs 51

Answers 51

2. Casting Processes 52

1. Introduction 52

2. Metals and Alloys That Can Be Cast 52

3. Manufacture of Castings 55

4. Classification of Solidification of Alloys 57

5. Some Problems in Casting 61

6. Heat Transfer in the Solidification Process 66

7. Riser Design and Riser Locations 73

8. Limitations of the Sand Casting Process 74

9. Other Casting Processes 78

10. Cleaning of Castings 80

11. Inspection of Castings 82

12. Casting of Copper and Copper Based Alloys 92

13. Casting Aluminium and Aluminium Based Alloys 97

Conclusion 109

References 110

MCQs 111

Answers 112

Contents

vi Advanced Manufacturing Technology

3. Forming Processes 113

1. Introduction 113

2. Casting vs. Forming 113

3. Processing Steel Ingots 118

4. Open Die Forging Processes 127

5. Closed Die Forging Processes 129

6. Rib and Web Type Forgings 131

7. Rolling 135

8. Other Rolling Processes 144

9. The Extrusion Process 147

10. Factors Affecting The Extrusion Load 151

11. Hydrostatic Extrusion 153

12. Design of Extrusion Tools 155

13. Temperature Variation in Extrusion 158

14. Unfavourable Flow Patterns: Generation of Defects 161

15. Wire Drawing 163

16. Sheet Metal Forming 169

17. Tools For Sheet Metal Forming 173

18. Non-Conventional Forming Processes 176

19. Metal Forming Equipment 180

Conclusion 186

References 186

MCQs 186

Answers 187

4. Welding, Joining and Non-Destructive Testing Processes 188

1. Introduction 188

2. Welding of Dissimilar Materials by Pressure Welding 190

3. Cold Pressure Welding 200

Conclusion 207

References 208

MCQs 208

Answers 209

5. Powder Metallurgy 210

1. Introduction 210

2. Characteristics of Metal Powders 211

3. Production of Metal Powder 212

4. Compaction of Powders 213

5. Sintering 219

6. High-Temperature Consolidation of Powders 222

7. Behaviour of Sintered Powder Compacts in Mechanical Working 223

Contents vii

Conclusion 225

References 226

MCQs 226

Answers 227

6. Plastic Injection Moulding 228

1. Introduction 228

2. Processing of Polymers 228

3. Behaviour of Plastics 232

4. Extrusion 235

5. Operating Point of the Extruder-die System 238

6. Dies for Extrusion 240

7. Characteristics of Polymers: Considerations in Diede-Sign 242

Conclusion 245

References 246

MCQs 246

Answers 247

7. Manufacturability and Process Selection 248

1. Introduction 248

2. Design for Manufacturability 250

3. Method of Selecting the Material 252

Conclusion 254

References 254

MCQs 254

Answers 255

8. Method of Selection of Manufacturing Processes 256

1. Introduction 256

2. Procedure for Manufacturing Process 256

3. Product Manufacture and Cost 257

4. Cost and Complexity Index 259

Conclusion 259

References 260

MCQs 260

Answers 261

9. Metallic Materials 262

1. Introduction 262

2. Nature of Metallic Materials 263

3. Behaviour of Metallic Materials 266

4. High-Temperature Processing 267

viii Advanced Manufacturing Technology

5. Low-Temperature Processing 270

Conclusion 272

References 272

MCQs 273

Answers 273

10. Effect of Chemical Composition 274

1. Introduction 274

2. Strengthening Mechanisms 280

Conclusion 282

References 282

MCQs 283

Answers 283

Index 285

Shirley Crooks earned her Ph.D. in Manufacturing Engineering from State University, Tulsa. She is a Senior Lecturer at Community College, Texcoco. She has about 17 years of research experience in engineering design, manufacturing processes, production engineering, metallurgy, machinery, manufacturing industries, and sustainable development. Crooks has contributed over 50 research papers and articles related to nonconventional as well as hybrid machining processes. She also works as a senior editor for various international journals.