Fundamentals of Modern Manufacturing

by Groover, Mikell P.

• ISBN13: 9781119128694
• ISBN10: 1119128692
• Edition: 6th
• Format: Loose-leaf
• Copyright: 2015-11-23
• Publisher: John Wiley & Sons Inc

Summary

Fundamentals of Modern Manufacturing: Materials, Processes, and Systems, 6th Edition, is designed for a first course or two-course sequence in Manufacturing at the junior level in Mechanical, Industrial, and Manufacturing Engineering curricula. As in preceding editions, the author's objective is to provide a treatment of manufacturing that is modern and quantitative. The book's modern approach is based on balanced coverage of the basic engineering materials, the inclusion of recently developed manufacturing processes and comprehensive coverage of electronics manufacturing technologies. The quantitative focus of the text is displayed in its emphasis on manufacturing science and its greater use of mathematical models and quantitative end-of-chapter problems. This text is an unbound, three hole punched version.

Author Biography

Mikell P. Groover is Professor of Industrial and Manufacturing Systems Engineering at Lehigh University, where he also serves as Director of the Manufacturing Technology Laboratory. He holds the following degrees all from Lehigh: B.A. in Arts and Science, B.S. in Mechanical Engineering, M.S. and Ph.D. in Industrial Engineering. He is a Registered Professional Engineer in Pennsylvania. His industrial experience includes full-time employment at Eastman Kodak Company as a Manufacturing Engineer. Since joining Lehigh, he has done consulting, research, and project work for a number of industrial companies including Ingersoll-Rand, Air Products & Chemicals, Bethlehem Steel, and Hershey Foods.

Table of Contents

1 Introduction and Overview of Manufacturing 1

1.1 What Is Manufacturing? 2

1.2 Materials in Manufacturing 6

1.3 Manufacturing Processes 9

1.4 Production Systems 14

1.5 Manufacturing Economics 17

Part I Material Properties and Product Attributes 26

2 The Nature of Materials 26

2.1 Atomic Structure and the Elements 26

2.2 Bonding between Atoms and Molecules 29

2.3 Crystalline Structures 31

2.4 Noncrystalline (Amorphous) Structures 36

2.5 Engineering Materials 37

3 Mechanical Properties of Materials 40

3.1 Stress–Strain Relationships 40

3.2 Hardness 53

3.3 Effect of Temperature on Properties 57

3.4 Fluid Properties 59

3.5 Viscoelastic Behavior of Polymers 61

4 Physical Properties of Materials 66

4.1 Volumetric and Melting Properties 66

4.2 Thermal Properties 69

4.3 Mass Diffusion 70

4.4 Electrical Properties 72

4.5 Electrochemical Processes 74

5 Dimensions, Surfaces, and Their Measurement 77

5.1 Dimensions, Tolerances, and Related Attributes 77

5.2 Conventional Measuring Instruments and Gages 78

5.3 Surfaces 85

5.4 Measurement of Surfaces 89

5.5 Effect of Manufacturing Processes 91

Part II Engineering Materials 94

6 Metals 94

6.1 Alloys and Phase Diagrams 95

6.2 Ferrous Metals 99

6.3 Nonferrous Metals 115

6.4 Superalloys 123

7 Ceramics 126

7.1 Structure and Properties of Ceramics 127

7.2 Traditional Ceramics 129

7.3 New Ceramics 131

7.4 Glass 133

7.5 Some Important Elements Related to Ceramics 136

8 Polymers 140

8.1 Fundamentals of Polymer Science and Technology 141

8.2 Thermoplastic Polymers 150

8.3 Thermosetting Polymers 155

8.4 Elastomers 158

8.5 Polymer Recycling and Biodegradability 162

9 Composite Materials 166

9.1 Technology and Classification of Composite Materials 167

9.2 Metal Matrix Composites 174

9.3 Ceramic Matrix Composites 176

9.4 Polymer Matrix Composites 177

Part III Solidification Processes 181

10 Fundamentals of Metal Casting 181

10.1 Overview of Casting Technology 182

10.2 Heating and Pouring 184

10.3 Solidification and Cooling 188

11 Metal Casting Processes 198

11.1 Sand Casting 198

11.2 Other Expendable-Mold Casting Processes 202

11.3 Permanent-Mold Casting Processes 207

11.4 Foundry Practice 215

11.5 Casting Quality 219

11.6 Castability and Casting Economics 221

11.7 Product Design Considerations 225

12 Glassworking 230

12.1 Raw Materials Preparation and Melting 230

12.2 Shaping Processes in Glassworking 231

12.3 Heat Treatment and Finishing 236

12.4 Product Design Considerations 237

13 Shaping Processes for Plastics 239

13.1 Properties of Polymer Melts 240

13.2 Extrusion 242

13.3 Production of Sheet and Film 251

13.4 Fiber and Filament Production (Spinning) 254

13.5 Coating Processes 255

13.6 Injection Molding 256

13.7 Compression and Transfer Molding 266

13.8 Blow Molding and Rotational Molding 268

13.9 Thermoforming 273

13.10 Casting 277

13.11 Polymer Foam Processing and Forming 278

13.12 Product Design Considerations 279

14 Processing of Polymer Matrix Composites and Rubber 285

14.1 Overview of PMC Processing 285

14.2 Open Mold Processes 289

14.3 Closed Mold Processes 293

14.4 Other PMC Shaping Processes 295

14.5 Rubber Processing and Shaping 299

14.6 Manufacture of Tires and Other Rubber Products 304

Part IV Particulate Processing of Metals and Ceramics 309

15 Powder Metallurgy 309

15.1 Characterization of Engineering Powders 310

15.2 Production of Metallic Powders 314

15.3 Conventional Pressing and Sintering 316

15.4 Alternative Pressing and Sintering Techniques 322

15.5 Materials and Products for Powder Metallurgy 325

15.6 Design Considerations in Powder Metallurgy 326

16 Processing of Ceramics and Cermets 331

16.1 Processing of Traditional Ceramics 331

16.2 Processing of New Ceramics 339

16.3 Processing of Cermets 341

16.4 Product Design Considerations 443

Part V Metal Forming and Sheet Metalworking 345

17 Fundamentals of Metal Forming 345

17.1 Overview of Metal Forming 345

17.2 Material Behavior in Metal Forming 348

17.3 Temperature in Metal Forming 349

17.4 Strain Rate Sensitivity 351

17.5 Friction and Lubrication in Metal Forming 353

18 Bulk Deformation Processes in Metal Working 356

18.1 Rolling 356

18.3 Forging 365

18.5 Extrusion 380

18.6 Wire and Bar Drawing 390

19 Sheet Metalworking 401

19.1 Cutting Operations 401

19.2 Bending Operations 408

19.3 Drawing 412

19.4 Dies and Presses for Sheet-Metal Processes 419

19.5 Other Sheet-Metal-Forming Operations 425

19.6 Sheet-Metal Operations Not Performed on Presses 428

19.7 Bending of Tube Stock 433

Part VI Material Removal Processes 439

20 Theory of Metal Machining 439

20.1 Overview of Machining Technology 441

20.2 Theory of Chip Formation in Metal Machining 444

20.3 Force Relationships and the Merchant Equation 448

20.4 Power and Energy Relationships in Machining 453

20.5 Cutting Temperature 455

21 Machining Operations and Machine Tools 459

21.1 Machining and Part Geometry 459

21.2 Turning and Related Operations 462

21.3 Drilling and Related Operations 470

21.4 Milling 475

21.5 Machining Centers and Turning Centers 482

21.6 Other Machining Operations 484

21.7 Machining Operations for Special Geometries 489

21.8 High-Speed Machining 495

22 Cutting-Tool Technology 500

22.1 Tool Life 500

22.2 Tool Materials 506

22.3 Tool Geometry 513

22.4 Cutting Fluids 523

23 Economic and Product Design Considerations in Machining 529

23.1 Machinability 529

23.2 Tolerances and Surface Finish 530

23.3 Machining Economics 535

23.4 Product Design Considerations in Machining 541

24 Grinding and Other Abrasive Processes 546

24.1 Grinding 546

24.2 Related Abrasive Processes 562

25 Nontraditional Machining and Thermal Cutting Processes 568

25.1 Mechanical Energy Processes 569

25.2 Electrochemical Machining Processes 572

25.3 Thermal Energy Processes 576

25.4 Chemical Machining 585

25.5 Application Considerations 590

Part VII Property Enhancing and Surface Processing Operations 595

26 Heat Treatment of Metals 595

26.1 Annealing 595

26.2 Martensite Formation in Steel 596

26.3 Precipitation Hardening 600

26.4 Surface Hardening 601

26.5 Heat Treatment Methods and Facilities 602

27 Surface Processing Operations 606

27.1 Industrial Cleaning Processes 606

27.2 Diffusion and Ion Implantation 610

27.3 Plating and Related Processes 611

27.4 Conversion Coating 615

27.5 Vapor Deposition Processes 616

27.6 Organic Coatings 622

27.7 Porcelain Enameling and Other Ceramic Coatings 624

27.8 Thermal and Mechanical Coating Processes 625

Part VIII Joining and Assembly Processes 628

28 Fundamentals of Welding 628

28.1 Overview of Welding Technology 629

28.2 The Weld Joint 631

28.3 Physics of Welding 634

28.4 Features of a Fusion-Welded Joint 637

29 Welding Processes 641

29.1 Arc Welding 641

29.2 Resistance Welding 650

29.3 Oxyfuel Gas Welding 657

29.4 Other Fusion-Welding Processes 661

29.5 Solid-State Welding 663

29.6 Weld Quality 669

29.7 Weldability and Welding Economics 673

29.8 Design Considerations in Welding 676

30 Brazing, Soldering, and Adhesive Bonding 681

30.1 Brazing 681

30.2 Soldering 686

30.3 Adhesive Bonding 690

31 Mechanical Assembly 697

31.1 Threaded Fasteners 697

31.2 Rivets and Eyelets 704

31.3 Assembly Methods Based on Interference Fits 705

31.4 Other Mechanical Fastening Methods 708

31.5 Molding Inserts and Integral Fasteners 709

31.6 Design for Assembly 710

Part IX Special Processing and Assembly Technologies 716

32 Rapid Prototyping and Additive Manufacturing 716

32.1 Fundamentals of Rapid Prototyping and Additive Manufacturing 717

32.2 Additive Manufacturing Processes 719

32.3 Cycle Time and Cost Analysis 726

32.4 Additive Manufacturing Applications 730

33 Processing of Integrated Circuits 734

33.1 Overview of IC Processing 735

33.2 Silicon Processing 738

33.3 Lithography 743

33.4 Layer Processes Used in IC Fabrication 747

33.5 Integrating the Fabrication Steps 753

33.6 IC Packaging 755

33.7 Yields in IC Processing 759

34 Electronics Assembly and Packaging 764

34.1 Electronics Packaging 764

34.2 Printed Circuit Boards 766

34.3 Printed Circuit Board Assembly 773

34.4 Electrical Connector Technology 780

35 Microfabrication Technologies 785

35.1 Microsystem Products 785

35.2 Microfabrication Processes 788

36 Nanofabrication Technologies 797

36.1 Nanotechnology Products and Applications 797

36.2 Introduction to Nanoscience 801

36.3 Nanofabrication Processes 805

Part X Manufacturing Systems 812

37 Automation Technologies for Manufacturing Systems 812

37.1 Automation Fundamentals 812

37.2 Hardware for Automation 815

37.3 Computer Numerical Control 819

37.4 Industrial Robotics 830

38 Integrated Manufacturing

38.1 Material Handling 838

38.2 Fundamentals of Production Lines 839

38.3 Manual Assembly Lines 841

38.4 Automated Production Lines 845

38.5 Cellular Manufacturing 849

38.6 Flexible Manufacturing Systems 853

38.7 Computer Integrated Manufacturing 857

Part XI Manufacturing Support Systems 861

39 Process Planning and Production Control 861

39.1 Process Planning 862

39.2 Other Manufacturing Engineering Functions 869

39.3 Production Planning and Control 872

39.4 Just-In-Time Delivery Systems 879

39.5 Lean Production 882

40 Quality Control and Inspection 887

40.1 Product Quality 887

40.2 Process Capability and Tolerances 888

40.3 Statistical Process Control 890

40.4 Quality Programs in Manufacturing 894

40.5 Inspection Principles 898

40.6 Modern Inspection Technologies 900

Appendix: Answers to Selected Problems 909

Index 913