Rent 9780201538465 | Manufacturing Engineering and Technology

Summary Table of Contents

Valuable suggestions and constructive criticism from numerous colleagues at various institutions, as well as the rapid progress in various areas of manufacturing, have led to the preparation of this third edition.

Preface	p. xvii
About the Authors	p. xx
General Introduction
What is Manufacturing?	p. 1
Examples of Manufactured Products	p. 6
The Design Process and Concurrent Engineering	p. 9
Design for Manufacture, Assembly, Disassembly, and Service	p. 13
Selecting Materials	p. 14
Selecting Manufacturing Processes	p. 18
... MOREComputer-Integrated Manufacturing	p. 24
Quality Assurance and Total Quality Management	p. 27
Global Competitiveness and Manufacturing Costs	p. 28
Lean Production and Agile Manufacturing	p. 29
Environmentally-Conscious Design and Manufacturing	p. 30
Product Liability	p. 31
Organization for Manufacture	p. 32
Fundamentals of Materials: Their Behavior and Manufacturing Properties	p. 36
The Structure of Metals	p. 39
Introduction	p. 39
The Crystal Structure of Metals	p. 40
Deformation and Strength of Single Crystals	p. 41
Grains and Grain Boundaries	p. 45
Plastic Deformation of Polycrystalline Metals	p. 47
Recovery, Recrystallization, and Grain Growth	p. 49
Cold-, Warm-, and Hot-Working	p. 50
Mechanical Behavior, Testing, and Manufacturing Properties of Materials	p. 55
Introduction	p. 55
Tension	p. 56
Compression	p. 66
Torsion	p. 67
Bending (Flexure)	p. 68
Hardness	p. 68
Fatigue	p. 73
Creep	p. 73
Impact	p. 75
Failure and Fracture of Materials in Manufacturing and Service	p. 75
Residual Stresses	p. 82
Work, Heat, and Temperature	p. 84
Physical Properties of Materials	p. 90
Introduction	p. 90
Density	p. 91
Melting Point	p. 94
Specific Heat	p. 94
Thermal Conductivity	p. 94
Thermal Expansion	p. 95
Electrical, Magnetic, and Optical Properties	p. 95
Corrosion Resistance	p. 97
Metal Alloys: Their Structure and Strengthening by Heat Treatment	p. 102
Introduction	p. 102
Structure of Alloys	p. 103
Phase Diagrams	p. 106
The Iron-Carbon System	p. 109
The Iron-Iron Carbide Phase Diagram and the Development of Microstructures in Steels	p. 111
Cast Irons	p. 113
Heat Treatment of Ferrous Alloys	p. 115
Hardenability of Ferrous Alloys	p. 120
Heat Treatment of Nonferrous Alloys and of Stainless Steels	p. 122
Case Hardening	p. 124
Annealing	p. 126
Heat-Treating Furnaces and Equipment	p. 130
Design Considerations for Heat Treating	p. 132
Ferrous Metals and Alloys: Production, General Properties and Applications	p. 137
Introduction	p. 137
Production of Iron and Steel	p. 138
Casting of Ingots	p. 141
Continuous Casting	p. 142
Carbon and Alloy Steels	p. 144
Stainless Steels	p. 148
Tool and Die Steels	p. 150
Nonferrous Metals and Alloys: Production, General Properties, and Applications	p. 156
Introduction	p. 156
Aluminum and Aluminum Alloys	p. 157
Magnesium and Magnesium Alloys	p. 161
Copper and Copper Alloys	p. 163
Nickel and Nickel Alloys	p. 164
Superalloys	p. 165
Titanium and Titanium Alloys	p. 166
Refractory Metals and Alloys	p. 168
Beryllium	p. 169
Zirconium	p. 170
Low-melting Alloys	p. 170
Precious Metals	p. 171
Shape-Memory Alloys	p. 172
Amorphous Alloys	p. 172
Nanomaterials	p. 172
Polymers: Structure, General Properties, and Applications	p. 177
Introduction	p. 177
The Structure of Polymers	p. 179
Thermoplastics	p. 186
Thermosetting Plastics	p. 190
Additives in Plastics	p. 190
General Properties and Applications of Thermoplastics	p. 191
General Properties and Applications of Thermosetting Plastics	p. 194
Biodegradable Plastics	p. 195
Elastomers (Rubbers)	p. 197
Ceramics, Graphite, and Diamond: Structure, General Properties, and Applications	p. 203
Introduction	p. 203
The Structure of Ceramics	p. 204
General Properties and Applications of Ceramics	p. 208
Glasses	p. 212
Glass Ceramics	p. 214
Graphite	p. 214
Diamond	p. 216
Composite Materials: Structure, General Properties, and Applications	p. 221
Introduction	p. 221
The Structure of Reinforced Plastics	p. 222
Properties of Reinforced Plastics	p. 227
Applications of Reinforced Plastics	p. 230
Metal-Matrix Composites	p. 232
Ceramic-Matrix Composites	p. 233
Other Composites	p. 233
Metal-Casting Processes and Equipment	p. 239
Fundamentals of Metal Casting	p. 241
Introduction	p. 241
Solidification of Metals	p. 242
Fluid Flow	p. 246
Fluidity of Molten Metal	p. 249
Heat Transfer	p. 250
Defects	p. 253
Metal-Casting Processes	p. 261
Introduction	p. 261
Sand Casting	p. 264
Shell-Mold Casting	p. 272
Expendable-Pattern Casting (Lost Foam)	p. 274
Plaster-Mold Casting	p. 276
Ceramic-Mold Casting	p. 276
Investment Casting	p. 278
Vacuum Casting	p. 281
Permanent-Mold Casting	p. 281
Slush Casting	p. 282
Pressure Casting	p. 282
Die Casting	p. 283
Centrifugal Casting	p. 286
Squeeze Casting and Semisolid-Metal Forming	p. 288
Casting Techniques for Single-Crystal Components	p. 290
Rapid Solidifcation (Amorphous Alloys)	p. 291
Inspection of Castings	p. 292
Melting Practice and Furnaces	p. 292
Foundries and Foundry Automation	p. 294
Metal Casting: Design, Materials, and Economics	p. 301
Introduction	p. 301
Design Considerations	p. 301
Casting Alloys	p. 306
The Economics of Casting	p. 310
Forming and Shaping Processes and Equipment	p. 316
Rolling of Metals	p. 320
Introduction	p. 320
Flat Rolling	p. 321
Flat-Rolling Practice	p. 326
Rolling Mills	p. 328
Shape-Rolling Operations	p. 331
Production of Seamless Tubing and Pipe	p. 334
Continuous Casting and Rolling; Integrated Mills and Minimills	p. 335
Forging of Metals	p. 340
Introduction	p. 340
Open-Die Forging	p. 342
Impression-Die and Closed-Die Forging	p. 344
Related Forging Operations	p. 348
Rotary Swaging	p. 351
Forging-Die Design	p. 353
Die Materials and Lubrication	p. 355
Forgeability	p. 355
Forging Machines	p. 357
Forging Practice and Process Capabilities	p. 360
Die Manufacturing Methods	p. 361
Die Failures	p. 362
The Economics of Forging	p. 363
Extrusion and Drawing of Metals	p. 369
Introduction	p. 369
The Extrusion Process	p. 371
Extrusion Practice	p. 363
Hot Extrusion	p. 374
Cold Extrusion	p. 377
Impact Extrusion	p. 379
Hydrostatic Extrusion	p. 380
Extrusion Defects	p. 380
Extrusion Equipment	p. 381
The Drawing Process	p. 382
Drawing Practice	p. 383
Defects and Residual Stresses	p. 386
Drawing Equipment	p. 386
Sheet-Metal Forming Processes	p. 392
Introduction	p. 392
Shearing	p. 394
Sheet-Metal Characteristics	p. 402
Test Methods for Formability of Sheet Metals	p. 404
Bending Sheet and Plate	p. 407
Common Bending Operations	p. 411
Tube Bending and Forming	p. 414
Stretch Forming	p. 416
Deep Drawing	p. 417
Rubber Forming	p. 423
Spinning	p. 424
Superplastic Forming	p. 427
Explosive, Magnetic-Pulse, Peen, and Other Forming Processes	p. 428
The Manufacturing of Honeycomb Structures	p. 431
The Dent Resistance of Sheet-Metal Parts	p. 432
Equipment for Sheet-Metal Forming	p. 432
The Economics of Sheet-Metal Forming Processes	p. 434
Processing of Powder Metals, Ceramics, Glass, and Superconductors	p. 440
Introduction	p. 440
Production of Metal Powders	p. 442
Compaction of Metal Powders	p. 446
Sintering	p. 453
Secondary and Finishing Operations	p. 456
Design Considerations for Powder Metallurgy	p. 458
Process Capabilities	p. 459
Economics of Powder Metallurgy	p. 460
Shaping Ceramics	p. 460
Forming and Shaping of Glass	p. 466
Techniques for Strengthening and Treating Glass	p. 470
Design Considerations for Ceramics and Glasses	p. 471
Processing of Superconductors	p. 472
Forming and Shaping Plastics and Composite Materials	p. 480
Introduction	p. 480
Extrusion	p. 481
Injection Molding	p. 485
Blow Molding	p. 489
Rotational Molding	p. 489
Thermoforming	p. 491
Compression Molding	p. 492
Transfer Molding	p. 493
Casting	p. 494
Cold Forming and Solid-Phase Forming	p. 495
Processing Elastomers	p. 495
Processing Reinforced Plastics	p. 496
Processing Metal-Matrix Composites	p. 503
Processing Ceramic-Matrix Composites	p. 504
Design Considerations and Economics of Forming and Shaping Plastics	p. 504
Rapid Prototyping Operations	p. 512
Introduction	p. 512
Subtractive Processes	p. 514
Additive Processes	p. 514
Virtual Prototyping	p. 523
Applications	p. 523
Material-Removal Processes and Machines	p. 531
Fundamentals of Cutting	p. 534
Introduction	p. 534
The Mechanics of Chip Formation	p. 537
The Types of Chips Produced in Metal-Cutting	p. 539
The Mechanics of Oblique Cutting	p. 544
Cutting Forces and Power	p. 545
Temperatures in Cutting	p. 549
Tool Life: Wear and Failure	p. 551
Surface Finish and Integrity	p. 558
Machinability	p. 560
Cutting-Tool Materials and Cutting Fluids	p. 569
Introduction	p. 569
Carbon and Medium-Alloy Steels	p. 573
High-Speed Steels	p. 573
Cast-Cobalt Alloys	p. 574
Carbides	p. 574
Coated Tools	p. 578
Alumina-Based Ceramics	p. 582
Cubic Boron Nitride	p. 583
Silicon-Nitride Based Ceramics	p. 584
Diamond	p. 584
Whisker-Reinforced Tool Materials	p. 585
Cutting-Tool Reconditioning	p. 585
Cutting Fluids	p. 585
Machining Processes Used to Produce Round Shapes	p. 594
Introduction	p. 594
Turning Parameters	p. 597
Lathes and Lathe Operations	p. 605
High-Speed Machining, Ultraprecision Machining, and Hard Turning	p. 619
Cutting Screw Threads	p. 622
Boring and Boring Machines	p. 626
Drilling and Drills	p. 627
Drilling Machines	p. 635
Reaming and Reamers	p. 636
Tapping and Taps	p. 638
Design Considerations for Drilling, Reaming and Tapping	p. 639
Machining Processes used to Produce Various Shapes	p. 646
Introduction	p. 646
Milling Operations	p. 647
Milling Machines	p. 661
Planing and Shaping	p. 663
Broaching and Broaching Machines	p. 664
Sawing	p. 668
Filing and Finishing	p. 670
Gear Manufacturing by Machining	p. 671
Machining and Turning Centers, Machine-Tool Structures, and Machining Economics	p. 682
Introduction	p. 682
Machining and Turning Centers	p. 682
Machine-Tool Structures	p. 690
Vibration and Chatter in Machining	p. 694
Machining Economics	p. 698
Abrasive Machining and Finishing Operations	p. 704
Introduction	p. 704
Abrasives	p. 706
Bonded Abrasives (Grinding Wheels)	p. 708
The Grinding Process	p. 712
Grinding Wheel Wear	p. 716
Grinding Operations and Machines	p. 721
Grinding Fluids	p. 729
Design Considerations for Grinding	p. 729
Ultrasonic Machining	p. 730
Finishing Operations	p. 731
Deburring	p. 735
Economics of Grinding and Finishing Operations	p. 738
Advanced Machining Processes and Nanofabrication	p. 744
Introduction	p. 744
Chemical Machining	p. 745
Electrochemical Machining	p. 750
Electrochemical Grinding	p. 753
Electrical-Discharge Machining	p. 754
Wire EDM	p. 757
Laser-Beam Machining	p. 758
Electron-Beam Machining and Plasma-Arc Cutting	p. 761
Water-Jet Machining	p. 761
Abrasive-Jet Machining	p. 763
Nanofabrication	p. 764
Micromachining	p. 765
The Economics of Advanced Machining Processes	p. 766
Joining Processes and Equipment	p. 771
Fusion Welding Processes	p. 775
Introduction	p. 775
Oxyfuel Gas Welding	p. 775
Arc-Welding Processes: Consumable Electrode	p. 779
Electrodes	p. 786
Arc-Welding Processes: Nonconsumable Electrode	p. 787
Thermit Welding	p. 790
Electron-Beam Welding	p. 790
Laser-Beam Welding	p. 791
Cutting	p. 792
Welding Safety	p. 794
Solid-State Welding Processes	p. 799
Introduction	p. 799
Cold Welding	p. 799
Ultrasonic Welding	p. 800
Friction Welding	p. 801
Resistance Welding	p. 803
Explosion Welding	p. 812
Diffusion Bonding (Welding)	p. 812
Diffusion Bonding/Superplastic Forming	p. 814
The Metallurgy of Welding: Welding Design and Process Selection	p. 819
Introduction	p. 819
The Welded Joint	p. 820
Weld Quality	p. 823
Weldability	p. 828
Testing Welded Joints	p. 830
Weld Design and Process Selection	p. 833
Brazing, Soldering, Adhesive Bonding, and Mechanical Fastening Processes	p. 839
Introduction	p. 839
Brazing	p. 840
Soldering	p. 844
Adhesive Bonding	p. 850
Mechanical Fastening	p. 856
Joining Plastics	p. 860
Surface Technology	p. 866
Surfaces: Their Nature, Roughness, and Measurement	p. 869
Introduction	p. 869
Surface Structure and Properties	p. 869
Surface Integrity	p. 871
Surface Texture	p. 872
Surface Roughness	p. 873
Tribology: Friction, Wear, and Lubrication	p. 882
Introduction	p. 882
Friction in Metals	p. 883
Friction in Plastics and Ceramics	p. 884
Reducing Friction	p. 884
Friction Measurement	p. 885
Wear	p. 887
Wear of Plastics and Ceramics	p. 890
Wear Measurement	p. 891
Lubrication	p. 891
Metalworking Fluids	p. 893
Solid Lubricants	p. 895
Conversion Coatings	p. 896
Lubricant Selection	p. 896
Surface Treatment, Coating and Cleaning	p. 902
Introduction	p. 902
Mechanical Surface Treatment and Coating	p. 903
Case Hardening and Hard Facing	p. 906
Thermal Spraying	p. 906
Vapor Deposition	p. 908
Ion Implantation	p. 911
Diffusion Coating	p. 911
Electroplating, Electroless Plating, and Electroforming	p. 911
Anodizing	p. 913
Conversion Coating	p. 914
Hot Dipping	p. 914
Porcelain Enameling, Ceramic Coating, and Organic Coatings	p. 915
Diamond Coating	p. 916
Painting	p. 917
Surface Texturing	p. 918
Cleaning Surfaces	p. 919
Fabrication of Microelectronic Devices	p. 924
Introduction	p. 924
Semiconductors and Silicon	p. 925
Crystal Growing and Wafer Preparation	p. 928
Film Deposition	p. 928
Oxidation	p. 930
Lithography	p. 931
Etching	p. 932
Diffusion and Ion Implantation	p. 933
Metallization and Testing	p. 934
Bonding and Packaging	p. 936
Yield and Reliability	p. 938
Printed Circuit Boards	p. 939
Common Aspects of Manufacturing	p. 943
Engineering Metrology and Instrumentation	p. 945
Introduction	p. 945
Measurement Standards	p. 946
Line-Graduated Instruments	p. 948
Comparative Length-Measuring Instruments	p. 951
Measuring Straightness, Flatness, Roundness, and Profile	p. 953
Coordinate Measuring and Layout Machines	p. 956
Gages	p. 958
Optical Instruments	p. 960
Automated Measurements	p. 960
General Characteristics and Selection of Measuring Instruments	p. 961
Geometric Dimensioning and Tolerancing	p. 961
Quality Assurance, Testing, and Inspection	p. 971
Introduction	p. 971
Product Quality	p. 972
Quality Assurance	p. 973
Total Quality Management	p. 974
Taguchi Methods	p. 976
The ISO and QS Standards	p. 980
Statistical Methods of Quality Control	p. 982
Statistical Process Control	p. 985
Reliability	p. 992
Nondestructive Testing	p. 992
Destructive Testing	p. 997
Automated Inspection	p. 998
Human Factors Engineering, Safety, and Product Liability	p. 1004
Introduction	p. 1004
Human-Factors Engineering	p. 1005
Safety	p. 1006
Environmental Considerations	p. 1009
Product Liability	p. 1011
Examples of Product Liability Claims	p. 1014
Manufacturing in a Competitive Environment	p. 1019
Automation of Manufacturing Processes	p. 1021
Introduction	p. 1021
Automation	p. 1023
Numerical Control	p. 1029
Programming for Numerical Control	p. 1036
Adaptive Control	p. 1038
Material Handling and Movement	p. 1041
Industrial Robots	p. 1043
Sensor Technology	p. 1051
Flexible Fixturing	p. 1054
Design for Assembly, Disassembly, and Service	p. 1056
Computer-Integrated Manufacturing Systems	p. 1067
Introduction	p. 1067
Manufacturing Systems	p. 1068
Computer-Integrated Manufacturing	p. 1069
Computer-Aided Design and Engineering	p. 1071
Computer-Aided Manufacturing	p. 1075
Computer-Aided Process Planning	p. 1076
Computer Simulation of Manufacturing Processes and Systems	p. 1079
Group Technology	p. 1079
Cellular Manufacturing	p. 1086
Flexible Manufacturing Systems	p. 1088
Just-in-Time Production	p. 1091
Communications Networks in Manufacturing	p. 1093
Artificial Intelligence	p. 1095
The Factory of the Future	p. 1099
Competitive Aspects of Manufacturing	p. 1106
Introduction	p. 1106
Selection of Materials	p. 1107
Product Design and Quantity of Material	p. 1110
Substitution of Materials	p. 1110
Selection of Manufacturing Processes	p. 1113
Process Capabilities	p. 1115
Manufacturing Costs	p. 1119
Value Engineering	p. 1123
Index	p. 1137
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