DeGarmo's Materials and Processes in Manufacturing, 10th Edition

by J. T. Black (Auburn University); Ronald A. Kohser (University of Missouri, Rolla)

• ISBN13: 9780470055120
• ISBN10: 047005512X
• Edition: 10th
• Format: Hardcover
• Copyright: 2007-03-01
• Publisher: Wiley

Summary

Through nine highly successful editions and now a new Tenth Edition, DeGarmo, Black, and Kohser\'s MATERIALS AND PROCESSES IN MANUFACTURING has built a strong reputation for its exceedingly clear presentation and highly practical approach to materials and processes. Completely revised and updated to reflect all current practices, standards, and materials, the Tenth Edition covers manufacturing processes, manufacturing systems, and materials for manufacturing. Through an exclusive arrangement between Society of Manufacturing Engineers and Wiley the Tenth Edition includes a DVD that is a 2 hr collection of video clips abridged from the SME Fundamental Manufacturing Processes video series. It contains approximately 20 clips of 5-6 minutes each.

Author Biography

J.T. Black received his Ph.D. from Mechanical and Industrial Engineering, University of Illinois, Urbana in 1969, an M.S. in Industrial Engineering from West Virginia University in 1963 and his B.S. in Industrial Engineering, Lehigh University in 1960. JT. is Professor Emeritus from Industrial and Systems Engineering in the Samuel Ginn College of Engineering at Auburn University. He was the Chairman and a Professor of Industrial and Systems Engineering at The University of Alabama-Huntsville He also taught at The Ohio State University, the University of Rhode Island, the University of Vermont, the University of Illinois and West Virginia University. JT. is a Fellow in the American Society of Mechanical Engineers, the Institute of Industrial Engineering and the Society of Manufacturing Engineers. J loves to write music (mostly down home country) and Poetry. Co-authoring with Ron Kohser makes this book a success, just as picking his doubles partner in tennis has given him #1 doubles ranking for 65 years olds in the State of Alabama.

Ron Kohser received his Ph.D. from the Lehigh University Institute for Metal Forming in 1975. Ron is currently in his 32nd year on the faculty of the University of Missouri-Rolla, where he is a Professor of Metallurgical Engineering and Dean's Teaching Scholar. While maintaining a full commitment to classroom instruction, he has served as department chair and Associate Dean for Undergraduate Instruction. He currently teaches courses in metallurgy for  Engineers, Introduction to Manufacturing academic responsibilities, Ron and h is wife Barb operate a Miner Indulgence, a bed-and-breakfast in Rolla, Missouri.

Table of Contents

Preface	p. vii
Introduction to DeGarmo's Materials and Processes in Manufacturing	p. 1
Materials, Manufacturing, and the Standard of Living	p. 1
Manufacturing and Production Systems	p. 3
Case Study: Famous Manufacturing Engineers	p. 27
Properties of Materials	p. 28
Introduction	p. 28
Static Properties	p. 30
Dynamic Properties	p. 42
Temperature Effects (Both High and Low)	p. 47
Machinability, Formability, and Weldability	p. 50
Fracture Toughness and the Fracture Mechanics Approach	p. 50
Physical Properties	p. 52
Testing Standards and Concerns	p. 53
Case Study: Separation of Mixed Materials	p. 55
Nature of Metals and Alloys	p. 56
Structure-Property-Processing-Performance Relationships	p. 56
The Structure of Atoms	p. 57
Atomic Bonding	p. 57
Secondary Bonds	p. 59
Atom Arrangements in Materials	p. 59
Crystal Structures of Metals	p. 59
Development of a Grain Structure	p. 61
Elastic Deformation	p. 62
Plastic Deformation	p. 63
Dislocation Theory of Slippage	p. 64
Strain Hardening or Work Hardening	p. 64
Plastic Deformation in Polycrystalline Metals	p. 65
Grain Shape and Anisotropic Properties	p. 66
Fracture of Metals	p. 66
Cold Working, Recrystallization, and Hot Working	p. 66
Grain Growth	p. 68
Alloys and Alloy Types	p. 68
Atomic Structure and Electrical Properties	p. 68
Equilibrium Phase Diagrams and the Iron-Carbon System	p. 71
Introduction	p. 71
Phases	p. 71
Equilibrium Phase Diagrams	p. 71
Iron-Carbon Equilibrium Diagram	p. 79
Steels and the Simplified Iron-Carbon Diagram	p. 80
Cast Irons	p. 82
Case Study: The Blacksmith Anvils	p. 88
Heat Treatment	p. 89
Introduction	p. 89
Processing Heat Treatments	p. 89
Heat Treatments Used to Increase Strength	p. 92
Strengthening Heat Treatments for Nonferrous Metals	p. 93
Strengthening Heat Treatments for Steel	p. 96
Surface Hardening of Steel	p. 109
Furnaces	p. 112
Heat Treatment and Energy	p. 114
Case Study: A Carpenter's Claw Hammer	p. 116
Ferrous Metals and Alloys	p. 118
Introduction to History-Dependent Materials	p. 118
Ferrous Metals	p. 118
Iron	p. 119
Steel	p. 120
Stainless Steels	p. 132
Tool Steels	p. 134
Alloy Cast Steels and Irons	p. 136
Case Study: Interior Tub of a Top-Loading Washing Machine	p. 138
Nonferrous Metals and Alloys	p. 139
Introduction	p. 139
Copper and Copper Alloys	p. 140
Aluminum and Aluminum Alloys	p. 144
Magnesium and Magnesium Alloys	p. 152
Zinc-Based Alloys	p. 154
Titanium and Titanium Alloys	p. 155
Nickel-Based Alloys	p. 157
Superalloys and Other Metals Designed for High-Temperature Service	p. 157
Lead and Tin, and Their Alloys	p. 158
Some Lesser Known Metals and Alloys	p. 159
Metallic Glasses	p. 159
Graphite	p. 160
Case Study: Nonsparking Wrench	p. 161
Nonmetallic Materials: Plastics, Elastomers, Ceramics, and Composites	p. 162
Introduction	p. 162
Plastics	p. 163
Elastomers	p. 173
Ceramics	p. 175
Composite Materials	p. 182
Case Study: Two-Wheel Dolly Handles	p. 194
Material Selection	p. 195
Introduction	p. 195
Material Selection and Manufacturing Processes	p. 197
The Design Process	p. 199
Procedures for Material Selection	p. 200
Additional Factors to Consider	p. 203
Consideration of the Manufacturing Process	p. 204
Ultimate Objective	p. 205
Materials Substitution	p. 207
Effect of Product Liability on Materials Selection	p. 207
Aids to Material Selection	p. 208
Case Study: Material Selection	p. 212
Measurement and Inspection and Testing	p. 213
Introduction	p. 213
Standards of Measurement	p. 214
Allowance and Tolerance	p. 220
Inspection Methods for Measurement	p. 227
Measuring Instruments	p. 229
Vision Systems for Measurement	p. 238
Coordinate Measuring Machines	p. 240
Angle-Measuring Instruments	p. 240
Gages for Attributes Measuring	p. 242
Testing	p. 245
Visual Inspection	p. 247
Liquid Penetrant Inspection	p. 247
Magnetic Particle Inspection	p. 248
Ultrasonic Inspection	p. 250
Radiography	p. 252
Eddy-Current Testing	p. 253
Acoustic Emission Monitoring	p. 255
Other Methods of Nondestructive Testing and Inspection	p. 256
Dormant versus Critical Flaws	p. 257
Case Study: Measuring An Angle	p. 261
Fundamentals of Casting	p. 262
Introduction to Materials Processing	p. 262
Introduction to Casting	p. 263
Casting Terminology	p. 265
The Solidification Process	p. 266
Patterns	p. 276
Design Considerations in Castings	p. 278
The Casting Industry	p. 280
Case Study: The Cast Oil-Field Fitting	p. 282
Expendable-Mold Casting Processes	p. 283
Introduction	p. 283
Sand Casting	p. 283
Cores and Core Making	p. 298
Other Expendable-Mold Processes with Multiple-Use Patterns	p. 302
Expendable-Mold Processes Using Single-Use Patterns	p. 304
Shakeout, Cleaning, and Finishing	p. 310
Summary	p. 310
Case Study: Movable and Fixed Jaw Pieces for a Heavy-Duty Bench Vise	p. 312
Multiple-Use-Mold Casting Processes	p. 313
Introduction	p. 313
Permanent-Mold Casting	p. 313
Die Casting	p. 316
Squeeze Casting and Semisolid Casting	p. 320
Centrifugal Casting	p. 322
Continuous Casting	p. 324
Melting	p. 325
Pouring Practice	p. 328
Cleaning, Finishing, and Heat Treating of Castings	p. 329
Automation in Foundry Operations	p. 330
Process Selection	p. 330
Case Study: Baseplate for a Household Steam Iron	p. 333
Fabrication of Plastics, Ceramics, and Composites	p. 334
Introduction	p. 334
Fabrication of Plastics	p. 334
Processing of Rubber and Elastomers	p. 346
Processing of Ceramics	p. 347
Fabrication of Composite Materials	p. 351
Case Study: Fabrication of Lavatory Wash Basins	p. 362
Fundamentals of Metal Forming	p. 363
Introduction	p. 363
Forming Processes: Independent Variables	p. 364
Dependent Variables	p. 366
Independent-Dependent Relationships	p. 366
Process Modeling	p. 367
General Parameters	p. 368
Friction and Lubrication under Metalworking Conditions	p. 369
Temperature Concerns	p. 371
Case Study: Repairs to a Damaged Propeller	p. 380
Bulk Forming Processes	p. 381
Introduction	p. 381
Classification of Deformation Processes	p. 381
Bulk Deformation Processes	p. 382
Rolling	p. 382
Forging	p. 389
Extrusion	p. 401
Wire, Rod, and Tube Drawing	p. 406
Cold Forming, Cold Forging, and Impact Extrusion	p. 409
Piercing	p. 413
Other Squeezing Processes	p. 414
Surface Improvement by Deformation Processing	p. 416
Case Study: Handle and Body of a Large Ratchet Wrench	p. 420
Sheet-Forming Processes	p. 421
Introduction	p. 421
Shearing Operations	p. 421
Bending	p. 430
Drawing and Stretching Processes	p. 437
Alternative Methods of Producing Sheet-Type Products	p. 451
Pipe Welding	p. 451
Presses	p. 452
Case Study: Fabrication of a One-Piece Brass Flashlight Case	p. 459
Powder Metallurgy	p. 460
Introduction	p. 460
The Basic Process	p. 461
Powder Manufacture	p. 461
Rapidly Solidified Powder (Microcrystalline and Amorphous)	p. 463
Powder Testing and Evaluation	p. 463
Powder Mixing and Blending	p. 463
Compacting	p. 464
Sintering	p. 468
Hot-Isostatic Pressing	p. 469
Other Techniques to Produce High-Density P/M Products	p. 470
Metal Injection Molding (MIM) or Powder Injection Molding (PIM)	p. 471
Secondary Operations	p. 473
Properties of P/M Products	p. 475
Design of Powder Metallurgy Parts	p. 476
Powder Metallurgy Products	p. 478
Advantages and Disadvantages of Powder Metallurgy	p. 478
Process Summary	p. 480
Case Study: Impeller for an Automobile Water Pump	p. 483
Electronic Electrochemical Chemical and Thermal Machining Processes	p. 484
Introduction	p. 484
Chemical Machining Processes	p. 485
Electrochemical Machining Processes	p. 504
Electrical Discharge Machining	p. 510
Case Study: Fire Extinguisher Pressure Gage	p. 522
Fundamentals of Machining/Orthogonal Machining	p. 523
Introduction	p. 523
Fundamentals	p. 524
Energy and Power in Machining	p. 533
Orthogonal Machining (Two Forces)	p. 538
Merchant's Model	p. 542
Mechanics of Machining (Statics)	p. 543
Shear Strain [Gamma] and Shear Front Angle [phi]	p. 545
Mechanics of Machining (Dynamics)	p. 547
Summary	p. 556
Case Study: Orthogonal Plate Machining Experiment at Auburn University	p. 559
Cutting Tools for Machining	p. 560
Introduction	p. 560
Cutting-Tool Materials	p. 565
Tool Geometry	p. 577
Tool Coating Processes	p. 578
Tool Failure and Tool Life	p. 582
Flank Wear	p. 583
Economics of Machining	p. 588
Cutting Fluids	p. 591
Case Study: Comparing Tool Materials Based on Tool Life	p. 597
Turning and Boring Processes	p. 598
Introduction	p. 598
Fundamentals of Turning, Boring, and Facing Turning	p. 600
Lathe Design and Terminology	p. 607
Cutting Tools for Lathes	p. 614
Workholding in Lathes	p. 619
Case Study: Estimating the Machining Time for Turning	p. 627
Drilling and Related Hole-Making Processes	p. 628
Introduction	p. 628
Fundamentals of the Drilling Process	p. 629
Types of Drills	p. 631
Tool Holders for Drills	p. 643
Workholding for Drilling	p. 645
Machine Tools for Drilling	p. 645
Cutting Fluids for Drilling	p. 649
Counterboring, Countersinking, and Spot Facing	p. 650
Reaming	p. 651
Case Study: Bolt-down Leg on a Casting	p. 655
Milling	p. 656
Introduction	p. 656
Fundamentals of Milling Processes	p. 656
Milling Tools and Cutters	p. 663
Machines for Milling	p. 669
Case Study: HSS versus Tungsten Carbide Milling	p. 676
Workholding Devices for Machine Tools	p. 677
Introduction	p. 677
Conventional Fixture Design	p. 677
Design Steps	p. 680
Clamping Considerations	p. 682
Chip Disposal	p. 683
Unloading and Loading Time	p. 684
Example of Jig Design	p. 684
Types of Jigs	p. 686
Conventional Fixtures	p. 688
Modular Fixturing	p. 690
Setup and Changeover	p. 691
Clamps	p. 694
Other Workholding Devices	p. 694
Economic Justification of Jigs and Fixtures	p. 698
Case Study: Fixture versus No Fixture in Milling	p. 701
Numerical Control (NC) and the A(4) Level of Automation	p. 702
Introduction	p. 702
Basic Principles of Numerical Control	p. 710
Machining Center Features and Trends	p. 721
Ultra-High-Speed Machining Centers (UHSMCs)	p. 725
Summary	p. 726
Case Study: Process Planning for the MfE	p. 730
Other Machining Processes	p. 731
Introduction	p. 731
Introduction to Shaping and Planing	p. 731
Introduction to Broaching	p. 736
Fundamentals of Broaching	p. 737
Broaching Machines	p. 742
Introduction to Sawing	p. 743
Introduction to Filing	p. 751
Case Study: Cost Estimating-Planing vs. Milling	p. 755
Abrasive Machining Processes	p. 756
Introduction	p. 756
Abrasives	p. 757
Grinding Wheel Structure and Grade	p. 763
Grinding Wheel Identification	p. 767
Grinding Machines	p. 771
Honing	p. 780
Superfinishing	p. 781
Free Abrasives	p. 783
Case Study: Overhead Crane Installation	p. 789
Thread and Gear Manufacturing	p. 790
Introduction	p. 790
Thread Making	p. 795
Internal Thread Cutting-Tapping	p. 798
Thread Milling	p. 803
Thread Grinding	p. 805
Thread Rolling	p. 805
Gear Making	p. 808
Gear Types	p. 811
Gear Manufacturing	p. 812
Machining of Gears	p. 813
Gear Finishing	p. 821
Gear Inspection	p. 823
Case Study: Bevel Gear for a Riding Lawn Mower	p. 826
Fundamentals of Joining	p. 827
Introduction to Consolidation Processes	p. 827
Classification of Welding and Thermal Cutting Processes	p. 828
Some Common Concerns	p. 828
Types of Fusion Welds and Types of Joints	p. 829
Design Considerations	p. 832
Heat Effects	p. 832
Weldability or Joinability	p. 839
Summary	p. 840
Gas Flame and Arc Processes	p. 842
Oxyfuel-Gas Welding	p. 842
Oxygen Torch Cutting	p. 846
Flame Straightening	p. 848
Arc Welding	p. 849
Consumable-Electrode Arc Welding	p. 851
Nonconsumable-Electrode Arc Welding	p. 859
Welding Equipment	p. 864
Arc Cutting	p. 865
Metallurgical and Heat Effects in Thermal Cutting	p. 867
Case Study: Bicycle Frame Construction and Repair	p. 870
Resistance and Solid-State Welding Processes	p. 871
Introduction	p. 871
Theory of Resistance Welding	p. 871
Resistance Welding Processes	p. 874
Advantages and Limitations of Resistance Welding	p. 879
Solid-State Welding Processes	p. 879
Case Study: Field Repair to a Power Transformer	p. 888
Other Welding Processes, Brazing and Soldering	p. 889
Introduction	p. 889
Other Welding and Cutting Processes	p. 889
Surface Modification by Welding-Related Processes	p. 898
Brazing	p. 901
Soldering	p. 909
Adhesive Bonding, Mechanical Fastening, and Joining of Nonmetals	p. 915
Adhesive Bonding	p. 915
Mechanical Fastening	p. 924
Joining of Plastics	p. 927
Joining of Ceramics and Glass	p. 929
Joining of Composites	p. 929
Case Study: Golf Club Heads with Insert	p. 932
Surface Engineering	p. 933
Introduction	p. 933
Mechanical Cleaning and Finishing Blast Cleaning	p. 940
Chemical Cleaning	p. 946
Coatings	p. 948
Vaporized Metal Coatings	p. 958
Clad Materials	p. 958
Textured Surfaces	p. 959
Coil-Coated Sheets	p. 959
Edge Finishing and Burrs	p. 959
Surface Integrity	p. 961
Case Study: Dana Lynn's Fatigue Lesson	p. 968
Quality Engineering	p. 969
Introduction	p. 969
Determining Process Capability	p. 970
Inspection to Control Quality	p. 981
Process Capability Determination from Control Chart Data	p. 985
Determining Causes for Problems in Quality	p. 986
Summary	p. 996
Case Study: Boring QC Chart Blunders	p. 1000
Manufacturing Automation (web-based chapter) (www.wiley.com/college/DeGarmo)
The Enterprise (web-based chapter) (www.wiley.com/college/DeGarmo)
Rapid Prototyping, Tooling And Fabrication (web-based chapter) (www.wiley.com/college/DeGarmo)
Selected References for Additional Study (web-based)
Index	p. 1001
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