9780130408716

"This new edition of Manufacturing Processes for Engineering Materials continues its tradition of balanced and comprehensive coverage of relevant engineering fundamentals, mathematical analysis, and traditional as well as advanced applications of manufacturing processes and operations. Updated and thoroughly edited for improved readability and clarity, this book is written mainly for students in mechanical, industrial, and metallurgical and materials engineering programs. The text continually emphasizes the important interactions among a wide variety of technical disciplines and the economics of manufacturing operations in an increasingly competitive global marketplace."--BOOK JACKET.

Serope Kalpakjian is a professor emeritus of mechanical and materials engineering at the Illinois Institute of Technology.

Preface

xiii

Introduction

1

(25)

What Is Manufacturing?

1

(5)

Product Design and Concurrent Engineering

6

(2)

Design for Manufacture, Assembly, Disassembly, and Service

8

(2)

Environmentally Conscious Design and Manufacturing

10

(1)

Selecting Materials

11

(3)

Selecting Manufacturing Processes

14

(3)

Computer-Integrated Manufacturing

17

(3)

Quality Assurance and Total Quality Management

20

(1)

Product Liability

21

(1)

Manufacturing Costs, Lean Production, and Agile Manufacturing

22

(1)

General Trends in Manufacturing

23

(1)

Responsibilities of Manufacturing Engineers

24

(2)

Summary

24

(2)

Fundamentals of the Mechanical Behavior of Materials

26

(55)

Introduction

26

(1)

Tension

27

(16)

Compression

43

(3)

Torsion

46

(2)

Bending

48

(1)

Hardness

49

(5)

Fatigue

54

(1)

Creep

55

(1)

Impact

56

(1)

Residual Stresses

57

(3)

Triaxial Stresses and Yield Criteria

60

(8)

Work of Deformation

68

(13)

Summary

72

(2)

Summary of Equations

74

(1)

Bibliography

75

(1)

Questions

75

(2)

Problems

77

(4)

Structure and Manufacturing Properties of Metals

81

(47)

Introduction

81

(1)

The Crystal Structure of Metals

82

(1)

Deformation and Strength of Single Crystals

83

(6)

Grains and Grain Boundaries

89

(3)

Plastic Deformation of Polycrystalline Metals

92

(1)

Recovery, Recrystallization, and Grain Growth

93

(2)

Cold, Warm, and Hot Working

95

(1)

Failure and Fracture

96

(7)

Physical Properties

103

(5)

Properties and Applications of Ferrous Alloys

108

(4)

Properties and Applications of Nonferrous Metals and Alloys

112

(16)

Summary

124

(1)

Summary of Equations

125

(1)

Bibliography

125

(1)

Questions

126

(1)

Problems

127

(1)

Surfaces, Tribology, Dimensional Characteristics, Inspection, and Product Quality Assurance

128

(58)

Introduction

128

(1)

Surface Structure and Properties

129

(1)

Surface Texture

130

(4)

Tribology: Friction, Wear, and Lubrication

134

(17)

Surface Treatments, Coatings, and Cleaning

151

(9)

Engineering Metrology and Instrumentation

160

(5)

Dimensional Tolerances

165

(2)

Testing and Inspection

167

(3)

Quality Assurance

170

(16)

Summary

180

(1)

Summary of Equations

181

(1)

Bibliography

182

(1)

Questions

183

(1)

Problems

184

(1)

Design

185

(1)

Metal-Casting Processes and Equipment; Heat Treatment

186

(74)

Introduction

186

(1)

Solidification of Metals

187

(8)

Cast Structures

195

(4)

Fluid Flow and Heat Transfer

199

(8)

Melting Practice and Furnaces

207

(2)

Casting Alloys

209

(6)

Ingot Casting and Continuous Casting

215

(3)

Casting Processes: Expendable Mold, Permanent Pattern

218

(6)

Casting Processes: Expendable Mold, Expendable Pattern

224

(3)

Casting Processes: Permanent Mold

227

(8)

Heat Treatment

235

(10)

Design Considerations

245

(4)

Economics of Casting

249

(11)

Case Study: Permanent-Mold Casting of Aluminum Automotive Pistons

250

(2)

Summary

252

(1)

Summary of Equations

253

(1)

Bibliography

254

(1)

Questions

254

(2)

Problems

256

(2)

Design

258

(2)

Bulk Deformation Processes

260

(76)

Introduction

260

(1)

Forging

260

(22)

Rolling

282

(18)

Extrusion

300

(12)

Rod, Wire, and Tube Drawing

312

(9)

Swaging

321

(1)

Die Manufacturing Methods

322

(2)

Die Failures

324

(12)

Case Study: Manufacturing Solid Rocket-Motor Case Segments for the Space Shuttle

325

(2)

Summary

327

(1)

Summary of Equations

328

(1)

Bibliography

329

(1)

Questions

330

(2)

Problems

332

(3)

Design

335

(1)

Sheet-Metal Forming Processes

336

(68)

Introduction

336

(1)

Sheet-Metal Characteristics

336

(5)

Shearing

341

(8)

Bending of Flat Sheet and Plate

349

(11)

Stretch Forming

360

(2)

Bulging

362

(1)

Rubber Forming and Hydroforming

363

(1)

Spinning

364

(4)

High-Energy-Rate Forming

368

(3)

Superplastic Forming

371

(1)

Various Forming Methods

372

(2)

Deep Drawing

374

(11)

Formability of Sheet Metals

385

(6)

Equipment for Sheet-Metal Forming

391

(1)

Design Considerations

392

(2)

Economics of Sheet-Metal Forming

394

(10)

Case Study: Can Manufacturing

394

(3)

Summary

397

(2)

Summary of Equations

399

(1)

Bibliography

399

(1)

Questions

400

(1)

Problems

401

(2)

Design

403

(1)

Material-Removal Processes: Cutting

404

(100)

Introduction

404

(1)

Mechanics of Chip Formation

405

(21)

Tool Wear and Failure

426

(8)

Surface Finish and Integrity

434

(3)

Machinability

437

(3)

Cutting-Tool Materials

440

(11)

Cutting Fluids

451

(3)

Cutting Processes and Machine Tools for Producing Round Shapes

454

(14)

Cutting Processes and Machine Tools for Producing Various Shapes

468

(14)

Machining and Turning Centers

482

(4)

Vibration and Chatter

486

(2)

Machine-Tool Structures

488

(1)

Design Considerations

489

(1)

Economics of Machining

490

(14)

Case Study: High-Speed Dry Machining of Cast-Iron Engine Blocks

493

(1)

Summary

494

(2)

Summary of Equations

496

(1)

Bibliography

497

(1)

Questions

498

(3)

Problems

501

(1)

Design

502

(2)

Material Removal Processes: Abrasive, Chemical, Electrical, and High-Energy Beams

504

(55)

Introduction

504

(1)

Abrasives

505

(1)

Bonded Abrasives

506

(4)

Mechanics of Grinding

510

(7)

Grinding-Wheel Wear

517

(4)

Grinding Operations and Machines

521

(6)

Ultrasonic Machining

527

(1)

Finishing Operations

528

(4)

Deburring

532

(1)

Chemical Machining

533

(4)

Electrochemical Machining

537

(2)

Electrochemical Grinding

539

(1)

Electrical-Discharge Machining

540

(4)

High-Energy-Beam Machining

544

(3)

Water-Jet, Abrasive Water-Jet, and Abrasive-Jet Machining

547

(2)

Design Considerations

549

(1)

Process Economics

549

(10)

Case Study: Manufacture of Stents

551

(2)

Summary

553

(1)

Summary of Equations

554

(1)

Bibliography

554

(1)

Questions

555

(2)

Problems

557

(1)

Design

558

(1)

Properties and Processing of Polymers and Reinforced Plastics; Rapid Prototyping and Rapid Tooling

559

(71)

Introduction

559

(1)

The Structure of Polymers

560

(8)

Thermoplastics: Behavior and Properties

568

(7)

Thermosets: Behavior and Properties

575

(1)

Thermoplastics: General Characteristics and Applications

576

(2)

Thermosets: General Characteristics and Applications

578

(1)

High-Temperature Polymers, Electrically Conducting Polymers, and Biodegradable Plastics

579

(2)

Elastomers (Rubbers): General Characteristics and Applications

581

(1)

Reinforced Plastics

582

(8)

Processing of Plastics

590

(15)

Processing of Polymer-Matrix-Reinforced Plastics

605

(5)

Rapid Prototyping and Rapid Tooling

610

(9)

Design Considerations

619

(2)

Economics of Processing Plastics

621

(9)

Case Study: The EPOCH Hip

622

(1)

Summary

623

(1)

Summary of Equations

624

(1)

Bibliography

625

(1)

Questions

626

(2)

Problems

628

(1)

Design

629

(1)

Properties and Processing of Metal Powders, Ceramics, Glasses, Composites, and Superconductors

630

(58)

Introduction

630

(1)

Production of Metal Powders

631

(5)

Compaction of Metal Powders

636

(8)

Sintering

644

(5)

Secondary and Finishing Operations

649

(2)

Design Considerations for Powder Metallurgy

651

(2)

Economics of Powder Metallurgy

653

(2)

Ceramics: Structure, Properties, and Applications

655

(8)

Shaping Ceramics

663

(5)

Glasses: Structure, Properties, and Applications

668

(3)

Forming and Shaping Glass

671

(4)

Design Considerations for Ceramics and Glasses

675

(1)

Graphite and Diamond

675

(1)

Processing Metal-Matrix and Ceramic-Matrix Composites

676

(3)

Processing Superconductors

679

(9)

Case Study: Production of High-Temperature Superconducting Tapes

679

(3)

Summary

682

(1)

Summary of Equations

683

(1)

Bibliography

683

(2)

Questions

685

(1)

Problems

686

(1)

Design

687

(1)

Joining and Fastening Processes

688

(65)

Introduction

688

(2)

Arc-Welding Processes: Consumable Electrode

690

(7)

Arc-Welding Processes: Nonconsumable Electrode

697

(2)

High-Energy-Beam Welding

699

(2)

The Fusion-Welded Joint

701

(11)

Cold Welding

712

(1)

Ultrasonic Welding

713

(1)

Friction Welding

714

(2)

Resistance Welding

716

(5)

Explosion Welding

721

(1)

Diffusion Bonding

722

(1)

Brazing and Soldering

723

(7)

Adhesive Bonding

730

(4)

Mechanical Fastening

734

(3)

Joining Plastics, Ceramics, and Glasses

737

(3)

Design Considerations in Joining

740

(3)

Economic Considerations

743

(10)

Case Study: Light-Curing Acrylic Adhesives for Medical Products

744

(2)

Summary

746

(1)

Bibliography

747

(2)

Questions

749

(2)

Problems

751

(1)

Design

752

(1)

Fabrication of Microelectronic and Micromechanical Devices

753

(55)

Introduction

753

(3)

Semiconductors and Silicon

756

(1)

Crystal Growing and Wafer Preparation

757

(2)

Films and Film Deposition

759

(2)

Oxidation

761

(1)

Lithography

762

(3)

Diffusion and Ion Implantation

765

(1)

Etching

766

(10)

Metallization and Testing

776

(2)

Wire Bonding and Packaging

778

(3)

Yield and Reliability of Chips

781

(1)

Printed Circuit Boards

782

(3)

Micromachining of MEMS Devices

785

(9)

The LIGA Microfabrication Process

794

(5)

Solid Free-Form Fabrication of Devices

799

(9)

Case Study: Accelerometer for Automotive Air Bags

800

(3)

Summary

803

(1)

Bibliography

804

(1)

Questions

805

(1)

Problems

806

(1)

Design

806

(2)

Automation of Manufacturing Processes and Systems

808

(44)

Introduction

808

(1)

Automation

809

(6)

Numerical Control

815

(6)

Programming for Numerical Control

821

(1)

Adaptive Control

822

(3)

Material Handling and Movement

825

(2)

Industrial Robots

827

(6)

Sensor Technology

833

(4)

Flexible Fixturing

837

(2)

Assembly, Disassembly, and Service

839

(3)

Design Considerations

842

(3)

Economic Considerations

845

(7)

Case Study: Development of a Modular Fixture

845

(2)

Summary

847

(1)

Bibliography

848

(1)

Questions

849

(1)

Design

850

(2)

Computer-Integrated Manufacturing Systems

852

(41)

Introduction

852

(1)

Manufacturing Systems

853

(1)

Computer-Integrated Manufacturing

854

(2)

Computer-Aided Design and Engineering

856

(5)

Computer-Aided Manufacturing

861

(1)

Computer-Aided Process Planning

861

(3)

Computer Simulation of Manufacturing Processes and Systems

864

(2)

Group Technology

866

(6)

Cellular Manufacturing

872

(2)

Flexible Manufacturing Systems

874

(2)

Just-in-Time Production

876

(2)

Communications Networks in Manufacturing

878

(2)

Artificial Intelligence

880

(3)

The Factory of the Future

883

(2)

Economic Considerations

885

(8)

Case Study: CAD Model Development for Automotive Components

886

(3)

Summary

889

(1)

Bibliography

890

(1)

Questions

891

(1)

Design

892

(1)

Product Design and Competitive Aspects of Manufacturing

893

(35)

Introduction

893

(1)

Product Design and Robust Design

894

(4)

Product Quality and Life Expectancy

898

(1)

Life-Cycle Assessment, Life-Cycle Engineering, and Sustainable Manufacturing

899

(2)

Selection of Materials for Products

901

(4)

Substitution of Materials in Products

905

(2)

Capabilities of Manufacturing Processes

907

(4)

Selection of Manufacturing Processes

911

(4)

Manufacturing Costs and Cost Reduction

915

(4)

Value Analysis

919

(9)

Case Study Concurrent Engineering for Intravenous Solution Containers

920

(2)

Summary

922

(1)

Bibliography

923

(1)

Questions

924

(1)

Design

925

(3)

Index

928

What is included with this book?

The New copy of this book will include any supplemental materials advertised. Please check the title of the book to determine if it should include any access cards, study guides, lab manuals, CDs, etc.

The Used, Rental and eBook copies of this book are not guaranteed to include any supplemental materials. Typically, only the book itself is included. This is true even if the title states it includes any access cards, study guides, lab manuals, CDs, etc.

The fourth edition of this text, like the previous editions, continues to make an attempt at presenting a comprehensive, balanced, and up-to-date coverage of the relevant fundamentals and real-world applications of engineering materials and manufacturing processes and systems and the analytical approaches involved. The topics covered throughout the 16 chapters reflect the rapid and significant advances that have taken place in various areas in manufacturing, and they are organized and described in such a manner to draw the interest of students. The case studies, mostly from industry, make the subject of manufacturing science arr4engineering less abstract by showing students the practical aspects of process applications. Integration of product design and manufacturing has justly resulted in greater recognition and prestige for these disciplines, and this edition therefore puts greater emphasis and better focus on this increasingly important subject. While studying this text, students should be able to assess the capabilities, limitations, and potential of production processes, including, particularly, the processes' economic and competitive aspects. The discussions throughout the chapters are aimed at motivating and challenging students to explore technically and economically viable solutions to a wide variety of important questions and problems in product design and manufacturing. This book has been written mainly for undergraduate students in mechanical, industrial, and metallurgical and materials engineering programs; it is also useful for graduate courses in manufacturing science and engineering. The text, as well as the numerous examples and case studies in each chapter, clearly shows that manufacturing engineering is an interdisciplinary and complex subject and that it is as important, exciting, and challenging as any other engineering discipline. What's new in this edition A new chapter has been added that covers the fabrication of microelectronic and micromechanical devices. The discussion of design considerations in each chapter have been expanded. Several new examples and case studies have been added throughout all chapters. A total of 1230 questions and problems has been added-30% more than in the third edition. Questions and problems now include a total of 140 design problems. Figures have been improved for better graphical impact. More cross-references to sections and chapters have been added throughout the text. All chapter bibliographies have been thoroughly updated. New or expanded topics for this edition include the following: Automated guided vehicles Biodegradable plastics Cryogenic machining and grinding Cryogenic treatment of cutting tools Design considerations for casting Design considerations for powder metallurgy Design considerations for sheet-metal forming Electrically conducting adhesives Enterprise resource planning Flexible fixturing ISO 9000 and 14000 standards Life-cycle assessment LIGA process Metal foams Microelectromechanical systems fabrication Microelectronics device fabrication Micromachining Modeling of casting Nanomaterials Plasma and wet etching Polymer processing Printed circuit boards Rapid protoyping and rapid tooling Rotary ultrasonic machining Silicon microstructure Six-sigma quality Solid free-form fabrication Stick-slip in extrusion Superconductor processing Surface-mount technology Value assessment Vibration and chatter in rolling Water-jet peening

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Manufacturing Processes for Engineering Materials

Manufacturing Processes for Engineering Materials

0130408719

Summary

Author Biography

Table of Contents

Supplemental Materials

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