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Materials & Manufacturing

Materials & Manufacturing for GATE Mechanical Engineering, one topic per lesson: the theory in plain words, the formulas, a solved example, and GATE-style questions (MCQ, MSQ and NAT) whose numerical answers are recomputed by a program when the site is built.

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1Materials

  1. Engineering Materials and TestingCrystal structures, the iron-carbon diagram, heat treatment of steels, mechanical properties, hardness and impact tests, and stress-strain behaviour of materials.

2Primary Processes

  1. Casting Processes and Gating DesignSand casting, patterns and allowances, gating system design with Bernoulli's equation, filling time, riser design with Chvorinov's rule, and special casting processes and defects.
  2. Metal Forming: Rolling, Forging and ExtrusionHot and cold working, flow stress, rolling (maximum draft, roll force), forging, extrusion and wire drawing forces, and sheet metal operations including blanking force and deep drawing.
  3. Welding and Joining ProcessesArc, gas, resistance and solid-state welding, heat input and arc power, resistance welding heat, heat-affected zone, weld defects, brazing, soldering and adhesive bonding.

3Machining

  1. Machining, Cutting Forces and Tool LifeOrthogonal cutting, chip thickness ratio and shear angle, Merchant's circle and cutting forces, specific energy, Taylor's tool life equation, machining time and surface finish.
  2. Non-Traditional Machining and MetrologyEDM, ECM, USM, AJM, LBM and EBM principles and MRR, limits, fits and tolerances, hole and shaft basis, gauges, surface roughness, comparators and interferometry.

4Computer Integrated Manufacturing

  1. CNC, CAD/CAM and Computer Integrated ManufacturingNC and CNC machines, part programming with G and M codes, CAD/CAM basics, group technology, flexible manufacturing systems, additive manufacturing and jigs and fixtures.