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Manufacturing Engineering and Technology

by ;
Edition:
4th
ISBN13:

9780201361315

ISBN10:
0201361310
Format:
Hardcover
Pub. Date:
1/1/2001
Publisher(s):
Pearson College Div
List Price: $122.00
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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.

Author Biography

Dr. Steven R. Schmid is an Associate Professor in the Department of Aerospace and Mechanical Engineering at the University of Notre Dame.

Table of Contents

Preface xvii
About the Authors xx
General Introduction
What is Manufacturing?
1(5)
Examples of Manufactured Products
6(3)
The Design Process and Concurrent Engineering
9(4)
Design for Manufacture, Assembly, Disassembly, and Service
13(1)
Selecting Materials
14(4)
Selecting Manufacturing Processes
18(6)
Computer-Integrated Manufacturing
24(3)
Quality Assurance and Total Quality Management
27(1)
Global Competitiveness and Manufacturing Costs
28(1)
Lean Production and Agile Manufacturing
29(1)
Environmentally-Conscious Design and Manufacturing
30(1)
Product Liability
31(1)
Organization for Manufacture
32(4)
Part I: Fundamentals of Materials: Their Behavior and Manufacturing Properties 36(203)
The Structure of Metals
39(16)
Introduction
39(1)
The Crystal Structure of Metals
40(1)
Deformation and Strength of Single Crystals
41(4)
Grains and Grain Boundaries
45(2)
Plastic Deformation of Polycrystalline Metals
47(2)
Recovery, Recrystallization, and Grain Growth
49(1)
Cold-, Warm-, and Hot-Working
50(5)
Mechanical Behavior, Testing, and Manufacturing Properties of Materials
55(35)
Introduction
55(1)
Tension
56(10)
Compression
66(1)
Torsion
67(1)
Bending (Flexure)
68(1)
Hardness
68(5)
Fatigue
73(1)
Creep
73(2)
Impact
75(1)
Failure and Fracture of Materials in Manufacturing and Service
75(7)
Residual Stresses
82(2)
Work, Heat, and Temperature
84(6)
Physical Properties of Materials
90(12)
Introduction
90(1)
Density
91(3)
Melting Point
94(1)
Specific Heat
94(1)
Thermal conductivity
94(1)
Thermal Expansion
95(1)
Electrical, Magnetic, and Optical Properties
95(2)
Corrosion Resistance
97(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


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