Manufacturing Science

UPSC syllabus for Mfg Sci
Manufacturing process: Machine tool engineering--Merchant's force analysis, Taylor's tool life equation; Conventional machining; NC and CNC machining process; jigs and fixtures
Non-conventional machining(ncm/ntm) -- EDM, ECM, ultrasonic, water jet machining etc; application of lasers and plasmas; energy rate calculations
Forming and welding processes--standard processes
Metrology--concept of fits and tolerances; tools and gauges; comparators; inspection of length, position, profile and surface finish
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My commentary:
The above syllabus is quite misleading.. Merchant, Taylor is only straightforward part. NC/CNC is a bit open ended, but still manageable. Jigs and fixtures topic is wide open. There are ignou notes for jigs and fixtures but the questions in exam seldom match this material.
NCM is alright.. one should not sweat too much over it. There is the book Manufacturing Science by Mr Amitabha Ghosh which is good.. a diagram, basic technical details, equations if any, advantages and limitations for each process.. that is it.. no more..
Not sure what "Energy rate calculations" means.. there is not much material on it..

Forming and welding processes-- there is forging, rolling, various types of welding-- theoretical questions and numericals(that are difficult to make sense). So, this short mention in syllabus is an atrocity. Put some extra time into understanding this section. I cant suggest any particular book, as I would use googlebooks search for each question and prepare in piecemeal fashion..

Metrology-- one section where one can hit ball out of stadium. Sure shot marks, if prepared well.
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Now some theory pages, some solved questions under topic categorization of my own..
I have also placed some questions from ESE and IFoS in sub topics without mentioning year etc.

A complete set of notes on manufacturing science: Mfg theory [7.5MB]

Casting theory
More on casting
CSE2011B5C10 solved

Forming
HERF
CSE2005B5b20 solved
Forging
CSE2007B6b30 solved
CSE2011B6c10 solved
CSE2009B7a10 solved
More on forging
Forging numericals
Rolling:
CSE2012B8b15 solved
CSE2006B8a20 solved
Tube mfg
CSE2010B6b30 unsolved
CSE2008B6b10 solved
Extrusion
CSE2012B8a15 solved
More on extrusion
Punching
CSE2011B5a10 solved

Welding
DC welding
CSE2008B6a30 solved
Gas welding
CSE2010B6a30 solved
CSE2011B7b20 solved
Flame cutting note
GTAW
CSE2009B7a10b unsolved
SMAW SAW
CSE2012B7b20 unsolved
Laser/plasma welding
CSE2007B6a30 solved
More on welding
Weld defects
per cent C equivalent

Jigs and fixtures note
CSE2012B5b12 solved
CSE2005B8b20 solved
321 location
CSE2009B8a20 solved
CSE2007B5a20 solved

Cutting:
Chip formation
CSE2008B5a20 solved
CSE2006B5b20 solved
Cutting ratio
CSE2009B5a20 solved
Turning tool
CSE2003B5b20 solved
Merchant
CSE2006B5a20 solved
CSE2005B5a20 solved
CSE2003B6a30 solved
CSE2003B6b30 solved
Tool life/Taylor
CSE2012B5a12 solved 2011B6d10 solved
CSE2010B5c12 solved
CSE2003B5a20 solved
Tool material
CSE2007B8a30 solved
More on cutting

Drilling:
CSE2012B6a10 solved   next page
CSE2006B6a30 solved

Milling:
CSE2009B5b20 solved
CSE2008B8a30 solved

Grinding:
CSE2012B6a20a    CSE2012B6a20b solved
More on grinding




Tool materials
CSE2007A4b15 solved
CSE2008A1d10 solved

Metrology
Fits and tolerances
CSE2011B5b10 solved CSE2011B5d10 solved
CSE2010B5d12 solved
CSE2007B7a30 solved
CSE2009B6a20 solved
CSE2005B8a20 solved
CSE2013B5e10 solved
CSE2012B5c12 solved
Metrology theory

NC machines
CSE2008B5b20 solved
CSE2011B6b10 solved
CSE2010B7a30 solved
CSE2005B6b15 solved
CSE2004B6a20 solved
CSE2011B7c10
CSE2005B6c15
CSE2004B6a10
CSE2012B8c10
CNC machines theory

Programming
CSE2007B5d20
CSE2006B8c20
CSE2005B8c20
CSE2004B8b30

Non Conventional Machining
EDM theory
CSE2012B6b20 solved
CSE2009B8a15 solved
CSE2006B6b30 solved
CSE2004B6b30 solved
AJM theory
CSE2011B5e10 solved
CSE2008B6b30 solved
ECM
CSE2011B8b20 solved CSE2008B6b5 solved
CSE2005B6a30 solved
USM
CSE2007B5b20 solved
PAM EBM LBM theory