Fundamentals of Modern Manufacturing: Materials, Processes, and Systems, 3rd Edition

by Mikell P. Groover (Professor of Industrial and Systems Engineering, Lehigh University)

• ISBN13: 9780471744856
• ISBN10: 0471744859
• Edition: 3rd
• Format: Hardcover
• Copyright: 2006-03-01
• Publisher: Wiley

Summary

In this introductory book, Groover not only takes a modern, all-inclusive look at manufacturing processes but also provides substantial coverage of engineering materials and production systems. It follows a more quantitative and design-oriented approach than other texts in the market, helping readers gain a better understanding of important concepts. They'll also discover how material properties relate to the process variables in a given process as well as how to perform manufacturing science and quantitative engineering analysis of manufacturing processes.

Author Biography

Mikell P. Groover is Professor of Industrial and Systems Engineering at Lehigh University, Where he also serves as Director of the George E. Kane Manufacturing Technology Laboratory and faculty member in the Manufacturing Systems Engineering Program. He received his B.A. in Arts and Science (1961), B.S. in Mechanical Engineering (1962), M.S. in Industrial Engineering (1966), and Ph.D. (1969), all from Lehigh. He is a Registered Professional Engineer in Pennsylvania. His industrial experience includes several years as a manufacturing engineer with Eastman Kodak Company. Since joining Lehigh, he has done consulting, research, and project work for a number of industrial companies.

His teaching and research areas include manufacturing processes, production systems, automation, material handling, facilities planning, and work systems. He has received a number of teaching awards at Lehigh University, as well as the Albert  G. Holzman Outstanding Educator Award from the Institute of Industrial Engineers (1995) and the SME Education Award from the Society of Manufacturing Engineers (2001). His publications include over 75 technical articles and seven books (listed below). His books are used throughout the world and have been translated into French, German, Spanish, Portuguese, Russian, Japanese, Korean, and Chinese. The first edition of the current book fundamentals of Modern Manufacturing received the IIE Joint Publishers Award (1996) and the M. Eugene Merchant Manufacturing Textbook Award from the Society of Manufacturing Engineers (1996).

Dr. Groover is a member of the Institute of Industrial Engineers, American Society of Mechanical Engineers (ASME), the Society of Manufacturing Engineers (SME), the North American Manufacturing Research Institute (NAMRI), and ASM International. He is a Fellow of IIE (1987) and SME (1996).

Table of Contents

Introduction and Overview of Manufacturing	1	(22)
What Is Manufacturing?	2	(6)
Materials in Manufacturing	8	(2)
Manufacturing Processes	10	(7)
Production Systems	17	(3)
Organization of the Book	20	(3)
Part I Material Properties and Product Attributes
The Nature of Materials	23	(15)
Atomic Structure and the Elements	23	(3)
Bonding between Atoms and Molecules	26	(2)
Crystalline Structures	28	(6)
Noncrystalline (Amorphous) Structures	34	(1)
Engineering Materials	35	(3)
Mechanical Properties of Materials	38	(29)
Stress-Strain Relationships	39	(12)
Hardness	51	(4)
Effect of Temperature on Properties	55	(2)
Fluid Properties	57	(3)
Viscoelastic Behavior of Polymers	60	(7)
Physical Properties of Materials	67	(12)
Volumetric and Melting Properties	68	(2)
Thermal Properties	70	(2)
Mass Diffusion	72	(2)
Electrical Properties	74	(1)
Electrochemical Processes	75	(4)
Dimensions, Tolerances, and Surfaces	79	(11)
Dimensions, Tolerances, and Related Attributes	80	(1)
Surfaces	81	(6)
Effect of Manufacturing Processes	87	(3)
Part II Engineering Materials
Metals	90	(37)
Alloys and Phase Diagrams	91	(5)
Ferrous Metals	96	(15)
Nonferrous Metals	111	(11)
Superalloys	122	(1)
Guide to the Processing of Metals	123	(4)
Ceramics	127	(17)
Structure and Properties of Ceramics	129	(2)
Traditional Ceramics	131	(2)
New Ceramics	133	(3)
Glass	136	(3)
Some Important Elements Related to Ceramics	139	(3)
Guide to Processing Ceramics	142	(2)
Polymers	144	(32)
Fundamentals of Polymer Science and Technology	147	(9)
Thermoplastic Polymers	156	(7)
Thermosetting Polymers	163	(4)
Elastomers	167	(7)
Guide to the Processing of Polymers	174	(2)
Composite Materials	176	(18)
Technology and Classification of Composite Materials	177	(8)
Metal Matrix Composites	185	(3)
Ceramic Matrix Composites	188	(1)
Polymer Matrix Composites	188	(3)
Guide to Processing Composite Materials	191	(3)
Part III Solidification Processes
Fundamentals of Metal Casting	194	(20)
Overview of Casting Technology	197	(2)
Heating and Pouring	199	(4)
Solidification and Cooling	203	(11)
Metal Casting Processes	214	(33)
Sand Casting	215	(5)
Other Expendable-Mold Casting Processes	220	(6)
Permanent-Mold Casting Processes	226	(8)
Foundry Practice	234	(4)
Casting Quality	238	(2)
Metals for Casting	240	(2)
Product Design Considerations	242	(5)
Glassworking	247	(10)
Raw Materials Preparation and Melting	247	(1)
Shaping Processes in Glassworking	248	(6)
Heat Treatment and Finishing	254	(1)
Product Design Considerations	255	(2)
Shaping Processes For Plastics	257	(50)
Properties of Polymer Melts	259	(2)
Extrusion	261	(10)
Production of Sheet and Film	271	(2)
Fiber and Filament Production (Spinning)	273	(2)
Coating Processes	275	(1)
Injection Molding	275	(11)
Compression and Transfer Molding	286	(2)
Blow Molding and Rotational Molding	288	(5)
Thermoforming	293	(4)
Casting	297	(1)
Polymer Foam Processing and Forming	298	(2)
Product Design Considerations	300	(7)
Rubber-Processing Technology	307	(12)
Rubber Processing and Shaping	307	(6)
Manufacture of Tires and Other Rubber Products	313	(3)
Product Design Considerations	316	(3)
Shaping Processes For Polymer Matrix Composites	319	(18)
Starting Materials for PMCs	321	(3)
Open Mold Processes	324	(3)
Closed Mold Processes	327	(3)
Filament Winding	330	(2)
Pultrusion Processes	332	(1)
Other PMC Shaping Processes	333	(4)
Part IV Particulate Processing of Metals and Ceramics
Powder Metallurgy	337	(25)
Characterization of Engineering Powders	340	(3)
Production of Metallic Powders	343	(2)
Conventional Pressing and Sintering	345	(6)
Alternative Pressing and Sintering Techniques	351	(3)
Materials and Products for PM	354	(1)
Design Considerations in Powder Metallurgy	355	(7)
Processing of Ceramics and Cermets	362	(16)
Processing of Traditional Ceramics	363	(7)
Processing of New Ceramics	370	(3)
Processing of Cermets	373	(2)
Product Design Considerations	375	(3)
Part V Metal Forming and Sheet Metalworking
Fundamentals of Metal Forming	378	(12)
Overview of Metal Forming	378	(3)
Material Behavior in Metal Forming	381	(1)
Temperature in Metal Forming	382	(2)
Strain Rate Sensitivity	384	(2)
Friction and Lubrication in Metal Forming	386	(4)
Bulk Deformation Processes in Metal Working	390	(50)
Rolling	391	(7)
Other Deformation Processes Related to Rolling	398	(2)
Forging	400	(12)
Other Deformation Processes Related to Forging	412	(4)
Extrusion	416	(11)
Wire and Bar Drawing	427	(13)
Sheet Metalworking	440	(41)
Cutting Operations	441	(7)
Bending Operations	448	(4)
Drawing	452	(7)
Other Sheet-Metal-Forming Operations	459	(3)
Dies and Presses for Sheet-Metal Processes	462	(7)
Sheet-Metal Operations Not Performed on Presses	469	(5)
Bending of Tube Stock	474	(7)
Part VI Material Removal Processes
Theory of Metal Machining	481	(24)
Overview of Machining Technology	483	(3)
Theory of Chip Formation in Metal Machining	486	(4)
Force Relationships and the Merchant Equation	490	(5)
Power and Energy Relationships in Machining	495	(3)
Cutting Temperature	498	(7)
Machining Operations and Machine Tools	505	(37)
Turning and Related Operations	508	(10)
Drilling and Related Operations	518	(4)
Milling	522	(7)
Machining Centers and Turning Centers	529	(2)
Other Machining Operations	531	(5)
High-Speed Machining	536	(6)
Cutting-Tool Technology	542	(32)
Tool Life	543	(6)
Tool Materials	549	(9)
Tool Geometry	558	(8)
Cutting Fluids	566	(8)
Economic and Product Design Considerations in Machining	574	(20)
Machinability	574	(3)
Tolerances and Surface Finish	577	(4)
Selection of Cutting Conditions	581	(6)
Product Design Considerations in Machining	587	(7)
Grinding and Other Abrasive Processes	594	(24)
Grinding	595	(17)
Related Abrasive Processes	612	(6)
Nontraditional Machining and Thermal Cutting Processes	618	(29)
Mechanical Energy Processes	619	(4)
Electrochemical Machining Processes	623	(4)
Thermal Energy Processes	627	(8)
Chemical Machining	635	(6)
Application Considerations	641	(6)
Part VII Property Enhancing and Surface Processing Operations
Heat Treatment of Metals	647	(13)
Annealing	648	(1)
Martensite Formation in Steel	648	(4)
Precipitation Hardening	652	(2)
Surface Hardening	654	(1)
Heat Treatment Methods and Facilities	655	(5)
Cleaning and Surface Treatments	660	(9)
Chemical Cleaning	660	(3)
Mechanical Cleaning and Surface Preparation	663	(2)
Diffusion and Ion Implantation	665	(4)
Coating and Deposition Processes	669	(20)
Plating and Related Processes	670	(4)
Conversion Coatings	674	(1)
Physical Vapor Deposition	675	(3)
Chemical Vapor Deposition	678	(3)
Organic Coatings	681	(2)
Porcelain Enameling and Other Ceramic Coatings	683	(1)
Thermal and Mechanical Coating Processes	684	(5)
Part VIII Joining and Assembly Processes
Fundamentals of Welding	689	(16)
Overview of Welding Technology	691	(2)
The Weld Joint	693	(3)
Physics of Welding	696	(3)
Features of a Fusion-Welded Joint	699	(6)
Welding Processes	705	(40)
Arc Welding	706	(10)
Resistance Welding	716	(7)
Oxyfuel Gas Welding	723	(3)
Other Fusion-Welding Processes	726	(3)
Solid-State Welding	729	(5)
Weld Quality	734	(5)
Weldability	739	(1)
Design Considerations in Welding	739	(6)
Brazing, Soldering, and Adhesive Bonding	745	(18)
Brazing	746	(5)
Soldering	751	(4)
Adhesive Bonding	755	(8)
Mechanical Assembly	763	(21)
Threaded Fasteners	764	(6)
Rivets and Eyelets	770	(2)
Assembly Methods Based on Interference Fits	772	(3)
Other Mechanical Fastening Methods	775	(1)
Molding Inserts and Integral Fasteners	776	(2)
Design for Assembly	778	(6)
Part IX Special Processing and Assembly Technologies
Rapid Prototyping	784	(14)
Fundamentals of Rapid Prototyping	785	(1)
Rapid Prototyping Technologies	786	(8)
Application Issues in Rapid Prototyping	794	(4)
Processing of Integrated Circuits	798	(32)
Overview of IC Processing	799	(4)
Silicon Processing	803	(4)
Lithography	807	(4)
Layer Processes Used in IC Fabrication	811	(7)
Integrating the Fabrication Steps	818	(2)
IC Packaging	820	(5)
Yields in IC Processing	825	(5)
Electronics Assembly and Packaging	830	(25)
Electronics Packaging	830	(2)
Printed Circuit Boards	832	(9)
Printed Circuit Board Assembly	841	(4)
Surface-Mount Technology	845	(5)
Electrical Connector Technology	850	(5)
Microfabrication Technologies	855	(15)
Microsystem Products	855	(6)
Microfabrication Processes	861	(9)
Nanofabrication Technologies	870	(17)
Introduction to Nanotechnology	872	(5)
Nanofabrication Processes	877	(7)
The National Nanotechnology Initiative	884	(3)
Part X Manufacturing Systems
Numerical Control and Industrial Robotics	887	(23)
Numerical Control	888	(12)
Industrial Robotics	900	(10)
Group Technology and Flexible Manufacturing Systems	910	(12)
Group Technology	910	(5)
Flexible Manufacturing Systems	915	(7)
Production Lines	922	(15)
Fundamentals of Production Lines	922	(4)
Manual Assembly Lines	926	(4)
Automated Production Lines	930	(7)
Part XI Manufacturing Support Systems
Manufacturing Engineering	937	(16)
Process Planning	938	(8)
Problem Solving and Continuous Improvement	946	(1)
Concurrent Engineering and Design for Manufacturability	946	(7)
Production Planning and Control	953	(19)
Aggregate Planning and the Master Production Schedule	955	(1)
Inventory Control	956	(4)
Material and Capacity Requirements Planning	960	(4)
Just-In-Time and Lean Production	964	(3)
Shop Floor Control	967	(5)
Quality Control	972	(17)
What Is Quality?	972	(1)
Process Capability	973	(1)
Statistical Tolerancing	974	(3)
Taguchi Methods	977	(3)
Statistical Process Control	980	(9)
Measurement and Inspection	989	(26)
Metrology	990	(3)
Inspection Principles	993	(2)
Conventional Measuring Instruments and Gages	995	(7)
Measurement of Surfaces	1002	(2)
Advanced Measurement and Inspection Technologies	1004	(11)
Index	1015