Manufacturing Engineering and Technology

by Kalpakjian, Serope; Schmid, Steven R.

• ISBN13: 9780201361315
• ISBN10: 0201361310
• Edition: 4th
• Format: Hardcover
• Copyright: 2001-01-01
• Publisher: Pearson College Div

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