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This article provides information on the operating principle, tool material and design changes, and safety and protection of various multifunction machines as well as the cutting fluids used. These include single-spindle automatic lathes, manual turret lathes, single-spindle automatic bar and chucking machines, Swiss-type automatic bar machines, multiple-spindle automatic bar and chucking machines, and multiple-spindle vertical chucking machines. The article provides examples that illustrate typical variations in dimensions obtained with a multiple-spindle machine. It also describes the machinability and provides information on the physical condition of the work metal. The article discusses the various factors to be considered in the selection of an appropriate machine. It presents examples that describe the techniques and equipment selected for specific production applications. In addition, the article discusses the types, applications, advantages, and disadvantages of machining centers and transfer machines. Finally, it provides the goals, objectives, and production techniques of flexible manufacturing systems.

Crucible furnaces, as compared to electric arc furnaces, are increasingly deployed in various melting practices due to their environmental and workplace friendliness and their process benefits. This article focuses on the application of induction crucible furnaces for melting and pouring operations in small-and medium-sized steel foundries, including aluminum, copper, and zinc industries. It also provides information on the process engineering benefits of melting and pouring operations.

This article discusses the principle, coil design, types and operation of a vacuum induction furnace. It describes the operation parameters that should be considered during the functioning of the induction furnace.

The crucible induction furnace is growing as an alternative melting unit to the cupola furnace due to its low specific power and reduced power consumption during solid melting material. This article details the process engineering features of the crucible induction furnace. It discusses the various processes involved in melting, holding, and pouring of liquid melt in crucible induction furnaces wherein the holding operation is carried out in channel furnace and pouring operation in pressure-actuated pouring furnaces. The article examines the behavior of furnace refractory lining to defects such as erosion, infiltration, crack formation, and clogging, and the corresponding preventive measures to avoid the occurrence of these defects. It elucidates the overall furnace operations, including commissioning, operational procedures, automatic process monitoring, inductor change, and dealing with disturbances.

Trimming is the removal of excess metal from a stamped part to allow the part to reach the finished stage or to prepare it for subsequent operations. This article presents an analysis of parts to be trimmed and describes the selection criteria for the different types of trimming dies such as conventional trimming dies and cam trimming dies. It provides information on rough and finish trimming and construction details of trimming dies. The article reviews the selection criteria of presses for a trimming operation. It provides a discussion on the scrap and material handling processes in trimming.

This article focuses on the mechanical and nonmechanical cutting methods used in metal fabrication industries. The most prevalent equipment used for mechanical cutting includes shears, iron workers, nibblers, and band saws. Nonmechanical methods of cutting include gas cutting, electric arc cutting, and laser cutting. The article concludes with information on the advantages of abrasive waterjet cutting, which is an alternative to laser cutting, gas cutting, and plasma cutting.

Thermal spray coatings are often modified or treated by a variety of post-coating operations to transform the as-coated material into a final product based on coating composition and application. This article provides a detailed description of the post-coating operations that fall under two basic categories: surface treatments, such as dimensional, non-dimensional, and geometric finishing; and internal treatments, such as sealing, heat treating, and peening. It also describes various inspection and testing methods, including destructive and non-destructive inspections, often employed after post-coating operations.

Thermal spray coating involves certain precoating operations, such as cleaning, surface preparation, and masking, that are critical to the overall quality of the coating system. In addition to these, certain other elements are considered prior to the coating, namely, customer requirements, coating function, part geometry, substrate metallurgy, structure, and thermal history. This article provides a detailed account of the various processes of surface preparation, namely, cleaning, roughening, dry abrasive grit blasting, and machining and macro roughening processes. It outlines the masking and fixturing techniques and stripping of coatings.