Manufacturing Engineering and Technology

by: Kalpakjian, Serope; Schmid, Steven R.

Manufacturing Engineering and Technology

by: Kalpakjian, Serope; Schmid, Steven R.

ISBN 13:
9780201361315
ISBN 10:
0201361310
Edition: 4th
Format: Hardcover
Copyright: 01/01/2001
Publisher: Pearson College Div
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Summary

Manufacturing Engineering and Technology describes both time-tested and modern methods of manufacturing engineering materials, and sets the standard for introducing readers to the scope and variety of manufacturing processes.

Preface

xvii

About the Authors

General Introduction

What is Manufacturing?

(5)

Examples of Manufactured Products

(3)

The Design Process and Concurrent Engineering

(4)

Design for Manufacture, Assembly, Disassembly, and Service

(1)

Selecting Materials

(4)

Selecting Manufacturing Processes

(6)

Computer-Integrated Manufacturing

(3)

Quality Assurance and Total Quality Management

(1)

Global Competitiveness and Manufacturing Costs

(1)

Lean Production and Agile Manufacturing

(1)

Environmentally-Conscious Design and Manufacturing

(1)

Product Liability

(1)

Organization for Manufacture

(4)

Part I: Fundamentals of Materials: Their Behavior and Manufacturing Properties

(203)

The Structure of Metals

(16)

Introduction

(1)

The Crystal Structure of Metals

(1)

Deformation and Strength of Single Crystals

(4)

Grains and Grain Boundaries

(2)

Plastic Deformation of Polycrystalline Metals

(2)

Recovery, Recrystallization, and Grain Growth

(1)

Cold-, Warm-, and Hot-Working

(5)

Mechanical Behavior, Testing, and Manufacturing Properties of Materials

(35)

Introduction

(1)

Tension

(10)

Compression

(1)

Torsion

(1)

Bending (Flexure)

(1)

Hardness

(5)

Fatigue

(1)

Creep

(2)

Impact

(1)

Failure and Fracture of Materials in Manufacturing and Service

(7)

Residual Stresses

(2)

Work, Heat, and Temperature

(6)

Physical Properties of Materials

(12)

Introduction

(1)

Density

(3)

Melting Point

(1)

Specific Heat

(1)

Thermal conductivity

(1)

Thermal Expansion

(1)

Electrical, Magnetic, and Optical Properties

(2)

Corrosion Resistance

(5)

Metal Alloys: Their Structure and Strengthening by Heat Treatment

102

(35)

Introduction

102

(1)

Structure of Alloys

103

(3)

Phase Diagrams

106

(3)

The Iron-Carbon System

109

(2)

The Iron-Iron carbide Phase Diagram and the Development of Microstructures in Steels

111

(2)

Cast Irons

113

(2)

Heat Treatment of Ferrous Alloys

115

(5)

Hardenability of Ferrous Alloys

120

(2)

Heat Treatment of Nonferrous Alloys and of Stainless Steels

122

(2)

Case Hardening

124

(2)

Annealing

126

(4)

Heat-Treating Furnaces and Equipment

130

(2)

Design Considerations for Heat Treating

132

(5)

Ferrous Metals and Alloys: Production, General Properties and Applications

137

(19)

Introduction

137

(1)

Production of Iron and Steel

138

(3)

Casting of Ingots

141

(1)

Continuous Casting

142

(2)

Carbon and Alloy Steels

144

(4)

Stainless Steels

148

(2)

Tool and Die Steels

150

(6)

Nonferrous Metals and Alloys: Production, General Properties, and Applications

156

(21)

Introduction

156

(1)

Aluminum and Aluminum Alloys

157

(4)

Magnesium and Magnesium Alloys

161

(2)

Copper and Copper Alloys

163

(1)

Nickel and Nickel Alloys

164

(1)

Superalloys

165

(1)

Titanium and Titanium Alloys

166

(2)

Refractory Metals and Alloys

168

(1)

Beryllium

169

(1)

Zirconium

170

(1)

Low-melting Alloys

170

(1)

Precious Metals

171

(1)

Shape-Memory Alloys

172

(1)

Amorphous Alloys

172

(1)

Nanomaterials

172

(5)

Polymers: Structure, General Properties, and Applications

177

(26)

Introduction

177

(2)

The Structure of Polymers

179

(7)

Thermoplastics

186

(4)

Thermosetting Plastics

190

(1)

Additives in Plastics

190

(1)

General Properties and Applications of Thermoplastics

191

(3)

General Properties and Applications of Thermosetting Plastics

194

(1)

Biodegradable Plastics

195

(2)

Elastomers (Rubbers)

197

(6)

Ceramics, Graphite, and Diamond: Structure, General Properties, and Applications

203

(18)

Introduction

203

(1)

Structure of Ceramics

204

(4)

General Properties and Applications of Ceramics

208

(4)

Glasses

212

(2)

Glass Ceramics

214

(1)

Graphite

214

(2)

Diamond

216

(5)

Composite Materials: Structure, General Properties, and Applications

221

(18)

Introduction

221

(1)

Structure of Reinforced Plastics

222

(5)

Properties of Reinforced Plastics

227

(3)

Applications of Reinforced Plastics

230

(2)

Metal-Matrix Composites

232

(1)

Ceramic-Matrix Composites

233

(1)

Other Composites

233

(6)

Part II: Metal-Casting Processes and Equipment

239

(77)

Fundamentals of Metal Casting

241

(20)

Introduction

241

(1)

Solidification of Metals

242

(4)

Fluid Plow

246

(3)

Fluidity of Molten Metal

249

(1)

Heat Transfer

250

(3)

Defects

253

(8)

Metal-Casting Processes

261

(40)

Introduction

261

(3)

Sand Casting

264

(8)

Shell-Mold Casting

272

(2)

Expendable-Pattern Casting (Lost Foam)

274

(2)

Plaster-Mold Casting

276

(1)

Ceramic-Mold Casting

276

(2)

Investment Casting

278

(3)

Vacuum Casting

281

(1)

Permanent-Mold Casting

281

(1)

Slush Casting

282

(1)

Pressure Casting

282

(1)

Die Casting

283

(3)

Centrifugal Casting

286

(2)

Squeeze Casting and Semisolid-Metal Forming

288

(2)

Casting Techniques for Single-Crystal Components

290

(1)

Rapid Solidification (Amorphous Alloys)

291

(1)

Inspection of Castings

292

(1)

Melting Practice and Furnaces

292

(2)

Foundries and Foundry Automation

294

(7)

Metal Casting: Design, Materials, and Economics

301

(15)

Introduction

301

(1)

Design Considerations

301

(5)

Casting Alloys

306

(4)

The Economics of Casting

310

(6)

Part III: Forming and Shaping Processes and Equipment

316

(215)

Roiling of Metals

320

(20)

Introduction

320

(1)

Flat Rolling

321

(5)

Flat-Rolling Practice

326

(2)

Rolling Mills

328

(3)

Shape-Rolling Operations

331

(3)

Production of Seamless Tubing and Pipe

334

(1)

Continuous Casting and Rolling; Integrated Mills and Minimills

335

(5)

Forging of Metals

340

(29)

Introduction

340

(2)

Open-Die Forging

342

(2)

Impression-Die and Closed-Die Forging

344

(4)

Related Forging Operations

348

(3)

Rotary Swaging

351

(2)

Forging-Die Design

353

(2)

Die Materials and Lubrication

355

(1)

Forgeability

355

(2)

Forging Machines

357

(3)

Forging Practice and Process Capabilities

360

(1)

Die Manufacturing Methods

361

(1)

Die Failures

362

(1)

The Economics of Forging

363

(6)

Extrusion and Drawing of Metals

369

(23)

Introduction

369

(2)

The Extrusion Process

371

Extrusion Practice

363

(11)

Hot Extrusion

374

(3)

Cold Extrusion

377

(2)

Impact Extrusion

379

(1)

Hydrostatic Extrusion

380

(1)

Extrusion Defects

380

(1)

Extrusion Equipment

381

(1)

The Drawing Process

382

(1)

Drawing Practice

383

(3)

Defects and Residual Stresses

386

(1)

Drawing Equipment

386

(6)

Sheet-Metal Forming Processes

392

(48)

Introduction

392

(2)

Shearing

394

(8)

Sheet-Metal Characteristics

402

(2)

Test Methods for Formability of Sheet Metals

404

(3)

Bending Sheet and Plate

407

(4)

Common Bending Operations

411

(3)

Tube Bending and Forming

414

(2)

Stretch Forming

416

(1)

Deep Drawing

417

(6)

Rubber Forming

423

(1)

Spinning

424

(3)

Superplastic Forming

427

(1)

Explosive, Magnetic-Pulse, Peen, and Other Forming Processes

428

(3)

The Manufacturing of Honeycomb Structures

431

(1)

The Dent Resistance of Sheet-Metal Parts

432

(1)

Equipment for Sheet-Metal Forming

432

(2)

The Economics of Sheet-Metal Forming Processes

434

(6)

Processing of Powder Metals, Ceramics, Glass, and Superconductors

440

(40)

Introduction

440

(2)

Production of Metal Powders

442

(4)

Compaction of Metal Powders

446

(7)

Sintering

453

(3)

Secondary and Finishing Operations

456

(2)

Design Considerations for Powder Metallurgy

458

(1)

Process Capabilities

459

(1)

Economics of Powder Metallurgy

460

(1)

Shaping Ceramics

460

(6)

Forming and Shaping of Glass

466

(4)

Techniques for Strengthening and Treating Glass

470

(1)

Design Considerations for Ceramics and Glasses

471

(1)

Processing of Superconductors

472

(8)

Forming and Shaping Plastics and Composite Materials

480

(32)

Introduction

480

(1)

Extrusion

481

(4)

Injection Molding

485

(4)

Blow Molding

489

(1)

Rotational Molding

489

(2)

Thermoforming

491

(1)

Compression Molding

492

(1)

Transfer Molding

493

(1)

Casting

494

(1)

Cold Forming and Solid-Phase Forming

495

(1)

Processing Elastomers

495

(1)

Processing Reinforced Plastics

496

(7)

Processing Metal-Matrix Composites

503

(1)

Processing Ceramic-Matrix Composites

504

(1)

Design Considerations and Economics of Forming and Shaping Plastics

504

(8)

Rapid Prototyping Operations

512

(19)

Introduction

512

(2)

Subtractive Processes

514

(1)

Additive Processes

514

(9)

Virtual Prototyping

523

(1)

Applications

523

(8)

Part IV: Material-Removal Processes and Machines

531

(240)

Fundamentals of Cutting

534

(35)

Introduction

534

(3)

The Mechanics of Chip Formation

537

(2)

The Types of Chips Produced in Metal-Cutting

539

(5)

The Mechanics of Oblique Cutting

544

(1)

Cutting Forces and Power

545

(4)

Temperatures in Cutting

549

(2)

Tool Life: Wear and Failure

551

(7)

Surface Finish and Integrity

558

(2)

Machinability

560

(9)

Cutting-Tool Materials and Cutting Fluids

569

(25)

Introduction

569

(4)

Carbon and Medium-Alloy Steels

573

(1)

High-Speed Steels

573

(1)

Cast-Cobalt Alloys

574

(1)

Carbides

574

(4)

Coated Tools

578

(4)

Alumina-Eased Ceramics

582

(1)

Cubic Boron Nitride

583

(1)

Silicon-Nitride Based Ceramics

584

(1)

Diamond

584

(1)

Whisker-Reinforced Tool Materials

585

(1)

Cutting-Tool Reconditioning

585

(1)

Cutting Fluids

585

(9)

Machining Processes Used to Produce Round Shapes

594

(52)

Introduction

594

(3)

Turning Parameters

597

(8)

Lathes and Lathe Operations

605

(14)

High-Speed Machining, Ultraprecision Machining, and Hard Turning

619

(3)

Cutting Screw Threads

622

(4)

Boring and Boring Machines

626

(1)

Drilling and Drills

627

(8)

Drilling Machines

635

(1)

Reaming and Reamers

636

(2)

Tapping and Taps

638

(1)

Design Considerations for Drilling, Reaming and Tapping

639

(7)

Machining Processes used to Produce Various Shapes

646

(36)

Introduction

646

(1)

Milling Operations

647

(14)

Milling Machines

661

(2)

Planing and Shaping

663

(1)

Broaching and Broaching Machines

664

(4)

Sawing

668

(2)

Filing and Finishing

670

(1)

Gear Manufacturing by Machining

671

(11)

Machining and Turning Centers, Machine-Tool Structures, and Machining Economics

682

(22)

Introduction

682

(1)

Machining and Turning Centers

682

(8)

Machine-Tool Structures

690

(4)

Vibration and Chatter in Machining

694

(4)

Machining Economics

698

(6)

Abrasive Machining and Finishing Operations

704

(40)

Introduction

704

(2)

Abrasives

706

(2)

Bonded Abrasives (Grinding Wheels)

708

(4)

The Grinding Process

712

(4)

Grinding Wheel Wear

716

(5)

Grinding Operations and Machines

721

(8)

Grinding Fluids

729

(1)

Design Considerations for Grinding

729

(1)

Ultrasonic Machining

730

(1)

Finishing Operations

731

(4)

Deburring

735

(3)

Economics of Grinding and Finishing Operations

738

(6)

Advanced Machining Processes and Nanofabrication

744

(27)

Introduction

744

(1)

Chemical Machining

745

(5)

Electrochemical Machining

750

(3)

Electrochemical Grinding

753

(1)

Electrical-Discharge Machining

754

(3)

Wire EDM

757

(1)

Laser-Beam Machining

758

(3)

Electron-Beam Machining and Plasma-Arc Cutting

761

(1)

Water-Jet Machining

761

(2)

Abrasive-Jet Machining

763

(1)

Nanofabrication

764

(1)

Micromachining

765

(1)

The Economics of Advanced Machining Processes

766

(5)

Part V: Joining Processes and Equipment

771

(95)

Fusion Welding Processes

775

(24)

Introduction

775

(1)

Oxyfuel Gas Welding

775

(4)

Arc-Welding Processes: Consumable Electrode

779

(7)

Electrodes

786

(1)

Arc-Welding Processes: Nonconsumable Electrode

787

(3)

Thermit Welding

790

(1)

Electron-Beam Welding

790

(1)

Laser-Beam Welding

791

(1)

Cutting

792

(2)

Welding Safety

794

(5)

Solid-State Welding Processes

799

(20)

Introduction

799

(1)

Cold Welding

799

(1)

Ultrasonic Welding

800

(1)

Friction Welding

801

(2)

Resistance Welding

803

(9)

Explosion Welding

812

(1)

Diffusion Bonding (Welding)

812

(2)

Diffusion Bonding/Superplastic Forming

814

(5)

The Metallurgy of Welding: Welding Design and Process Selection

819

(20)

Introduction

819

(1)

The Welded joint

820

(3)

Weld Quality

823

(5)

Weldability

828

(2)

Testing Welded Joints

830

(3)

Weld Design and Process Selection

833

(6)

Brazing, Soldering, Adhesive Bonding, and Mechanical Fastening Processes

839

(27)

Introduction

839

(1)

Brazing

840

(4)

Soldering

844

(6)

Adhesive Bonding

850

(6)

Mechanical Fastening

856

(4)

Joining Plastics

860

(6)

Part VI: Surface Technology

866

(77)

Surfaces: Their Nature, Roughness, and Measurement

869

(13)

Introduction

869

(1)

Surface Structure and Properties

869

(2)

Surface Integrity

871

(1)

Surface Texture

872

(1)

Surface Roughness

873

(9)

Tribology: Friction, Wear, and Lubrication

882

(20)

Introduction

882

(1)

Friction in Metals

883

(1)

Friction in Plastics and Ceramics

884

(1)

Reducing Friction

884

(1)

Friction Measurement

885

(2)

Wear

887

(3)

Wear of Plastics and Ceramics

890

(1)

Wear Measurement

891

(1)

Lubrication

891

(2)

Metalworking Fluids

893

(2)

Solid Lubricants

895

(1)

Conversion Coatings

896

(1)

Lubricant Selection

896

(6)

Surface Treatment, Coating and Cleaning

902

(22)

Introduction

902

(1)

Mechanical Surface Treatment and Coating

903

(3)

Case Hardening and Hard Facing

906

(1)

Thermal Spraying

906

(2)

Vapor Deposition

908

(3)

Ion Implantation

911

(1)

Diffusion Coating

911

(1)

Electroplating, Electroless Plating, and Electroforming

911

(2)

Anodizing

913

(1)

Conversion Coating

914

(1)

Hot Dipping

914

(1)

Porcelain Enameling, Ceramic Coating, and Organic Coatings

915

(1)

Diamond Coating

916

(1)

Painting

917

(1)

Surface Texturing

918

(1)

Cleaning Surfaces

919

(5)

Fabrication of Microelectronic Devices

924

(19)

Introduction

924

(1)

Semiconductors and Silicon

925

(3)

Crystal Growing and Wafer Preparation

928

(1)

Film Deposition

928

(2)

Oxidation

930

(1)

Lithography

931

(1)

Etching

932

(1)

Diffusion and Ion Implantation

933

(1)

Metallization and Testing

934

(2)

Bonding and Packaging

936

(2)

Yield and Reliability

938

(1)

Printed Circuit Boards

939

(4)

Part VII: Common Aspects of Manufacturing

943

(76)

Engineering Metrology and Instrumentation

945

(26)

Introduction

945

(1)

Measurement Standards

946

(2)

Line-Graduated Instruments

948

(3)

Comparative Length-Measuring Instruments

951

(2)

Measuring Straightness, Flatness, Roundness, and Profile

953

(3)

Coordinate Measuring and Layout Machines

956

(2)

Gages

958

(2)

Optical Instruments

960

(1)

Automated Measurements

960

(1)

General Characteristics and Selection of Measuring Instruments

961

(1)

Geometric Dimensioning and Tolerancing

961

(10)

Quality Assurance, Testing, and Inspection

971

(33)

Introduction

971

(1)

Product Quality

972

(1)

Quality Assurance

973

(1)

Total Quality Management

974

(2)

Taguchi Methods

976

(4)

The ISO and QS Standards

980

(2)

Statistical Methods of Quality Control

982

(3)

Statistical Process Control

985

(7)

Reliability

992

(1)

Nondestructive Testing

992

(5)

Destructive Testing

997

(1)

Automated Inspection

998

(6)

Human Factors Engineering, Safety, and Product Liability

1004

(15)

Introduction

1004

(1)

Human-Factors Engineering

1005

(1)

Safety

1006

(3)

Environmental Considerations

1009

(2)

Product Liability

1011

(3)

Examples of Product Liability Claims

1014

(5)

Part VIIIs: Manufacturing in a Competitive Environment

1019

(118)

Automation of Manufacturing Processes

1021

(46)

Introduction

1021

(2)

Automation

1023

(6)

Numerical Control

1029

(7)

Programming for Numerical Control

1036

(2)

Adaptive Control

1038

(3)

Material Handling and Movement

1041

(2)

Industrial Robots

1043

(8)

Sensor Technology

1051

(3)

Flexible Fixturing

1054

(2)

Design for Assembly, Disassembly, and Service

1056

(11)

Computer-Integrated Manufacturing Systems

1067

(39)

Introduction

1067

(1)

Manufacturing Systems

1068

(1)

Computer-Integrated Manufacturing

1069

(2)

Computer-Aided Design and Engineering

1071

(4)

Computer-Aided Manufacturing

1075

(1)

Computer-Aided Process Planning

1076

(3)

Computer Simulation of Manufacturing Processes and Systems

1079

(1)

Group Technology

1079

(7)

Cellular Manufacturing

1086

(2)

Flexible Manufacturing Systems

1088

(3)

Just-in-Time Production

1091

(2)

Communications Networks in Manufacturing

1093

(2)

Artificial Intelligence

1095

(4)

The Factory of the Future

1099

(7)

Competitive Aspects of Manufacturing

1106

(31)

Introduction

1106

(1)

Selection of Materials

1107

(3)

Product Design and Quantity of Material

1110

(1)

Substitution of Materials

1110

(3)

Selection of Manufacturing Processes

1113

(2)

Process capabilities

1115

(4)

Manufacturing Costs

1119

(4)

Value Engineering

1123

(14)

Index

1137

Manufacturing Engineering and Technology

Manufacturing Engineering and Technology

9780201361315

0201361310

Summary

Author Biography

Table of Contents

Supplemental Materials

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Manufacturing Engineering and Technology

Manufacturing Engineering and Technology

9780201361315

0201361310

Summary

Author Biography

Table of Contents

Supplemental Materials

Write a Review

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