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Modern Materials and Manufacturing Processes,9780130946980
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Modern Materials and Manufacturing Processes

by ; ; ;
Edition:
3rd
ISBN13:

9780130946980

ISBN10:
0130946982
Format:
Hardcover
Pub. Date:
8/25/2003
Publisher(s):
Prentice Hall

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This is the 3rd edition with a publication date of 8/25/2003.
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Summary

This book introduces the current state-of-the-art technology in materials and manufacturing processes with an emphasis on the rapidly growing technologies in the plastics and aerospace industries. It takes a unique approach by presenting specific materials and manufacturing processes, then progresses into a discussion of the ways in which these materials and processes are integrated into today's functioning manufacturing industry.KEY TOPICSA four-part organization presents materials and their applications; covers specific manufacturing processes; emphasizes tolerances, measurement, and calibration; and discusses the design, tooling, and production aspects of manufacturing.For individuals preparing for an engineering technology career.

Table of Contents

Introduction: The Importance of Training and Education in the High-Technology World 1(14)
The Manufacturing Economy: Past, Present, and Future
2(1)
The Computer's Influence in Manufacturing
3(1)
Manufacturing Technology Today and Tomorrow
4(3)
The Manufacturing Industry
7(4)
Manufacturing and You
11(4)
Part I Materials of Manufacture 15(124)
Chapter 1 The Atomic Structures of Materials
17(14)
Structure and Classification of Atoms
18(1)
The Atom
18(1)
Periodic Table
18(2)
Atomic Bonding
20(2)
Metals
22(1)
Solidification of Metals
23(2)
Polymers
25(3)
Ceramics
28(3)
Chapter 2 Properties of Metals
31(22)
Mechanical Properties
31(10)
Physical Properties
41(2)
Metallurgical Microscopy
43(1)
Nondestructive Testing
44(9)
Chapter 3 Changing the Properties of Metals
53(18)
Heating and Cooling of Metals
54(1)
The Iron-Carbon Phase Diagram
55(2)
Nonferrous Phase Diagrams
57(1)
Principles of Heat Treating
58(1)
Heat Treating Ferrous Metals
58(6)
Solution Heat Treating and Precipitation Hardening (Hardening Nonferrous Metals)
64(2)
Strengthening by Plastic Deformation and Alloying
66(3)
Annealing
69(3)
Heating Equipment
72
Chapter 4 Mining and Extraction of Metals
71(20)
Ores and Mining
77(3)
Extraction of Iron
80(1)
Steelmaking
81(9)
Extraction of Aluminum
90(1)
Extraction of Copper and Nickel
91(1)
Extraction of Lead and Zinc
92(1)
Extraction of Magnesium
92(1)
Space-Age Metals
92
Chapter 5 Extraction and Refinement of Common Nonmetallic Materials
91(26)
Petrochemicals
98(1)
Polymers
98(9)
Plastic Finishes
107(1)
Engineering Properties of Plastics
107(1)
Elastomers and Adhesives
108(3)
Petroleum Products
111(1)
Ceramic Materials
112(1)
Wood Products
113(4)
Chapter 6 Selection and Application of Materials
117(22)
Classification Systems for Metals
117(1)
Carbon and Alloy Steels
118(1)
Tool Steels
118(1)
Structural Steels
119(1)
HSLA Steels
120(1)
Stainless Steels
120(1)
Cast Irons
121(2)
Nonferrous Metals
123(6)
Materials Identification
129(3)
Fluid Analysis
132(3)
Materials Applications
135(4)
Part II Survey of Manufacturing Processes 139(226)
Chapter 7 Design Specifications and the Capability of the Manufacturing Process
141(4)
Product Specifications
141(1)
The Capability of the Manufacturing Process
142(3)
Chapter 8 Processing of Metals: Casting
145(24)
The Casting Process
145(1)
Patterns
146(1)
Sand Casting
147(5)
Evaporative Casting Process
152(1)
Shell Process
152(1)
Permanent Mold Casting
153(2)
Slush Casting
155(1)
Centrifugal Casting
155(1)
Investment Casting
156(2)
Shaw Process
158(1)
Die Casting
158(4)
Furnaces and Metal Handling
162(2)
Molten Metal Safety
164(1)
Pouring Practice
165(1)
Casting Cleanup
165(1)
Casting Design and Problems
165(4)
Chapter 9 Processing of Metals: Hot Working
169(26)
Hot Rolling
170(3)
Strand Casting
173(3)
Recrystallization
176(1)
Forging Processes
177(4)
Forging Dies
181(2)
Upset Forging
183(4)
Swaging
187(2)
Hot Extrusion
189(1)
Hot Drawing
190(1)
Hot Spinning
191(1)
Seamless Tubing
191(1)
Pipe Welding (Roll Forming)
191(4)
Chapter 10 Processing of Metals: Cold Working
195(30)
Factors in Cold Working
195(2)
Cold Rolling in the Steel Mill
197(3)
Cold Rolling of Nonferrous Metals
200(1)
Blanking and Pressing
200(2)
Drawing, Forming, and Extruding Metal
202(10)
Miscellaneous Metal-Working Processes
212(13)
Chapter 11 Powder Metallurgy
225(10)
How PIM Parts Are Made
225(1)
Metal Powders
226(1)
Powder Compaction
227(3)
Sintering
230(1)
Secondary Operations
230(1)
P/M Products and Their Uses
231(1)
Factors in Design of P/M Products
232(3)
Chapter 12 Principles of Machining Processes
235(14)
Motion and Parameters: Speed, Feed, and Depth of Cut
239(1)
Machining: Shearing Chips from the Workpiece
240(2)
Cutting Tool Materials
242(2)
Cutting Tool Geometry
244(2)
Cutting Fluids
246(1)
Appendix: Calculation of Speeds and Feeds for Machining Operations
246(3)
Chapter 13 Machine Tool Operations
249(42)
Basic Machine Tools
250(7)
Turning Machines and Equipment
257(13)
Milling Machines and Equipment
270(2)
Shapers and Planers
272(1)
Broaching
273(1)
Gears
274(7)
Abrasive Machining
281(3)
Honing, Lapping, and Superfinishing
284(7)
Chapter 14 Nontraditional Manufacturing Processes
291(8)
Electrodischarge Machining
291(2)
Electrochemical Machining (ECM) and Electrochemical Deburring (ECDB)
293(1)
Electrolytic Grinding (ELG)
294(1)
Lasers and Laser Machining
295(2)
Ultrasonic Machining
297(1)
Water Jet Machining and Abrasive Water Jet Machining
297(1)
Electron Beam Machining
297(1)
Plasma Technology
297(2)
Chapter 15 Joining Processes
299(28)
Mechanical Fasteners
299(7)
Adhesive Bonding
306(3)
Welding Processes
309(14)
Brazing and Soldering
323(1)
Thermal Spraying
324(1)
Welding Plastics
325(2)
Chapter 16 Processing of Plastics and Composites
327(18)
The Changing World of Plastic and Composite Materials
327(2)
Processing Methods for Plastics
329(7)
Composite Processing Methods
336(4)
Composite Applications
340(3)
Tool and Die Making for Plastics and Composite Processing
343(2)
Chapter 17 Processing of Other Industrial Materials
345(10)
Glass
345(2)
Ceramics
347(1)
Wood, Wood Products, and Paper
348(3)
Fabrics
351(1)
Rubber
351(1)
Natural Materials
352(1)
Construction Materials
352(3)
Chapter 18 Corrosion and Protection of Materials
355(10)
Metal Corrosion
355(1)
Protection Methods
356(5)
Preparing Materials for Surface Protection
361(4)
Part III Measurement and Quality Assurance 365(28)
Chapter 19 Quality Assurance and Control
367(6)
Source Inspection before Manufacturing
367(2)
Quality Control during Manufacturing
369(2)
Product Service and Warranties after Manufacturing
371(1)
Product Testing
372(1)
Chapter 20 Inspection and Measurement
373(20)
Inspection
374(1)
Comparison Inspection
374(2)
Measurement, Precision, and Resolution
376(1)
Measurement of Dimensions in Manufacturing Operations
377(13)
Calibration, Standards, Interchangeability, and Traceability
390(3)
Part IV Manufacturing Systems 393(48)
Chapter 21 Product and Process Design
395(24)
Product Design
395(1)
The Product Design Sequence
396(5)
The Blueprint
401(3)
Preparing for Manufacturing
404(3)
Process Design
407(2)
Manufacturing Execution
409(10)
Chapter 22 Automation in Manufacturing
419(22)
Factors in Automation
419(2)
Automation Systems in Manufacturing
421(10)
CIM and Flexible Manufacturing Systems for the Integrated Factory
431(3)
Industrial Robots
434(3)
The Production Line and Mass Production
437(4)
Glossary 441(17)
Index 458

Excerpts

Modern Materials and Manufacturing Processes, Third Edition,presents state-of-the art technology in materials and manufacturing processes. Written for engineering technology and vocational students, the text is descriptive in nature and relies more on descriptive material than analysis. The book covers a broad range of materials and processes and includes plentiful illustrations.This text discusses both traditional and recently developed materials and processes. In addition to presenting the specific materials and processes of manufacturing normally included in a survey course, the text, in a unique approach, shows how those materials and processes are integrated into today's functioning manufacturing industry. This makes the text a good fit for a survey course for engineering technology and vocational students covering both materials and manufacturing processes.Modern Materials and Manufacturing Processesis organized to present clear, sequential course material for any teaching system, whether competency-based or traditional. Objectives and key words at the beginning of each chapter clarify the goals of each chapter and familiarize the student with important terminology encountered on each topic. Over 1000 illustrations and photographs complement the text. Case studies and case problems are included where appropriate to promote student thought and discussion. Questions and case problems may be used for review or examination purposes. An extensive and newly enhanced glossary, including approximately 160 new terms, concludes the book. New to This Edition New and updated illustrations throughout. Complete glossary: approximately 160 new terms/definitions. Glossary terms appear in boldface in text. New Key Words feature begins each chapter. Each chapter has introductory summary of the chapter's content to improve the pedagogy of the material. New Introduction chapter. Expanded coverage of ceramics, plastics, and composites. New Chapter 7, Design Specifications and the Capability of the Manufacturing Process, explains the importance of precision before the subsequent chapters cover manufacturing processes. Parts II and III have been reversed so that manufacturing processes are covered before measurement and quality assurance. New Chapter 22 covers automation and mass production. Material has been reordered and updated throughout to be more logical and complete. Content and OrganizationPart I, Materials of Manufacture,discusses the basic materials used in manufacturing: metals, plastics, and ceramics. Chapters 1-3 identify and classify these materials by their atomic makeup, similarities, and differences. Chapters 4 and 5 explain how the materials are extracted from raw materials, and how the materials are processed. Chapter 6 reviews the many classification systems used for common metallic materials, and then discusses the properties and characteristics that lead to their selection and application.The detailed coverage in Part I allows the student to proceed to a study of product manufacturing that uses these materials. Where appropriate, newly developed materials, processes, and methods are presented throughout the text.Part II, Survey of Manufacturing Processes,discusses specific manufacturing processes and their capabilities. Chapter 7 is a new chapter on the specifications used in design and their relationship to the capabilities of the manufacturing process to be used. Subsequent chapters cover casting, cold and hot forming, forging, powdered metal processes, machining, plastics manufacturing, the joining of materials, and non-traditional manufacturing processes. Chapter 18 on the corrosion and protection of metals concludes Part II.Part III, Measurement and Quality Assurance,Chapters 19 and 20 introduce measurement and quality assuranc


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