Fundamentals of Modern Manufacturing: Materials, Processes, and Systems, 2nd Edition Update

by Mikell P. Groover (Lehigh University)

• ISBN13: 9780471656548
• ISBN10: 0471656542
• Edition: 2nd
• Format: Hardcover
• Copyright: 2003-12-01
• Publisher: Wiley

Summary

Reflecting the increasing importance of ceramics, polymers, composites, and silicon in manufacturing, Fundamentals of Modern Manufacturing Second Edition provides a comprehensive treatment of these other materials and their processing, without sacrificing its solid coverage of metals and metal processing. Topics include such modern processes as rapid prototyping, microfabrication, high speed machining and nanofabrication. Additional features include: Emphasis on how material properties relate to the process variables in a given process. Emphasis on manufacturing science and quantitative engineering analysis of manufacturing processes. More than 500 quantitative problems are included as end of chapter exercises. Multiple choice quizzes in all but one chapter (approximately 500 questions). Coverage of electronics manufacturing, one of the most commercially important areas in today's technology oriented economy. Historical notes are included to introduce manufacturing from the earliest materials and processes, like woodworking, to the most recent.

Author Biography

Mikell P. Groover is Professor of Industrial and Manufacturing Systems Engineering and Director of the George E. Kane Manufacturing Technology Laboratory at Lehigh University

Table of Contents

Introduction	1	(23)
What Is Manufacturing?	2	(6)
Materials in Manufacturing	8	(2)
Manufacturing Processes	10	(7)
Production Systems	17	(3)
Organization of the Book	20	(1)
Images of Manufacturing	21	(3)
Part I Material Properties and Product Attributes
The Nature of Materials	24	(15)
Atomic Structure and the Elements	24	(2)
Bonding between Atoms and Molecules	26	(3)
Crystalline Structures	29	(5)
Noncrystalline (amorphous) Structures	34	(2)
Engineering Materials	36	(3)
Mechanical Properties of Materials	39	(27)
Stress-Strain Relationships	39	(13)
Hardness	52	(3)
Effect of Temperature on Properties	55	(2)
Fluid Properties	57	(3)
Viscoelastic Behavior of Polymers	60	(6)
Physical Properties of Materials	66	(11)
Volumetric and Melting Properties	66	(3)
Thermal Properties	69	(2)
Mass Diffusion	71	(1)
Electrical Properties	72	(2)
Electrochemical Processes	74	(3)
Dimensions, Tolerances, and Surfaces	77	(11)
Dimensions, Tolerances, and Related Attributes	77	(1)
Surfaces	78	(7)
Effect of Manufacturing Processes	85	(3)
Part II Engineering Materials
Metals	88	(37)
Alloys and Phase Diagrams	89	(4)
Ferrous Metals	93	(16)
Nonferrous Metals	109	(11)
Superalloys	120	(2)
Guide to the Processing of Metals	122	(3)
Ceramics	125	(18)
Structure and Properties of Ceramics	127	(2)
Traditional Ceramics	129	(3)
New Ceramics	132	(2)
Glass	134	(4)
Some Important Elements Related to Ceramics	138	(2)
Guide to Processing Ceramics	140	(3)
Polymers	143	(32)
Fundamentals of Polymer Science and Technology	145	(10)
Thermoplastic Polymers	155	(7)
Thermosetting Polymers	162	(3)
Elastomers	165	(7)
Guide to the Processing of Polymers	172	(3)
Composite Materials	175	(18)
Technology and Classification of Composite Materials	176	(8)
Metal Matrix Composites	184	(2)
Ceramic Matrix Composites	186	(1)
Polymer Matrix Composites	187	(3)
Guide to Processing Composite Materials	190	(3)
Part III Solidification Processes
Fundamentals of Metal Casting	193	(20)
Overview of Casting Technology	196	(2)
Heating and Pouring	198	(4)
Solidification and Cooling	202	(11)
Metal Casting Processes	213	(33)
Sand Casting	214	(5)
Other Expendable Mold Casting Processes	219	(6)
Permanent Mold Casting Processes	225	(8)
Foundry Practice	233	(3)
Casting Quality	236	(3)
Metals for Casting	239	(1)
Product Design Considerations	240	(6)
Glassworking	246	(10)
Raw Materials Preparation and Melting	246	(1)
Shaping Processes in Glassworking	247	(6)
Heat Treatment and Finishing	253	(1)
Product Design Considerations	254	(2)
Shaping Processes for Plastics	256	(50)
Properties of Polymer Melts	258	(2)
Extrusion	260	(10)
Production of Sheet and Film	270	(2)
Fiber and Filament Production (spinning)	272	(2)
Coating Processes	274	(1)
Injection Molding	275	(10)
Compression and Transfer Molding	285	(2)
Blow Molding and Rotational Molding	287	(5)
Thermoforming	292	(4)
Casting	296	(1)
Polymer Foam Processing and Forming	297	(2)
Product Design Considerations	299	(7)
Rubber Processing Technology	306	(11)
Rubber Processing and Shaping	306	(5)
Manufacture of Tires and Other Rubber Products	311	(4)
Product Design Considerations	315	(2)
Shaping Processes for Polymer Matrix Composites	317	(17)
Starting Materials for PMCs	319	(2)
Open Mold Processes	321	(4)
Closed Mold Processes	325	(2)
Filament Winding	327	(2)
Pultrusion Processes	329	(2)
Other PMC Shaping Processes	331	(3)
Part IV Particulate Processing of Metals and Ceramics
Powder Metallurgy	334	(24)
Characterization of Engineering Powders	336	(4)
Production of Metallic Powders	340	(2)
Conventional Pressing and Sintering	342	(6)
Alternative Pressing and Sintering Techniques	348	(3)
Materials and Products for PM	351	(1)
Design Considerations in Powder Metallurgy	352	(6)
Processing of Ceramics and Cermets	358	(16)
Processing of Traditional Ceramics	359	(7)
Processing of New Ceramics	366	(3)
Processing of Cermets	369	(2)
Product Design Considerations	371	(3)
Part V Metal Forming and Sheet Metalworking
Fundamentals of Metal Forming	374	(12)
Overview of Metal Forming	374	(3)
Material Behavior in Metal Forming	377	(1)
Temperature in Metal Forming	378	(2)
Strain Rate Sensitivity	380	(3)
Friction and Lubrication in Metal Forming	383	(3)
Bulk Deformation Processes in Metal Working	386	(49)
Rolling	387	(8)
Other Deformation Processes Related to Rolling	395	(2)
Forging	397	(11)
Other Deformation Processes Related to Forging	408	(5)
Extrusion	413	(10)
Wire and Bar Drawing	423	(12)
Sheet Metal Working	435	(40)
Cutting Operations	436	(6)
Bending Operations	442	(5)
Drawing	447	(7)
Other Sheet-Metal-Forming Operations	454	(3)
Dies and Presses for Sheet Metal Processes	457	(6)
Sheet-Metal Operations Not Performed on Presses	463	(6)
Bending of Tube Stock	469	(6)
Part VI Material Removal Processes
Theory of Metal Machining	475	(24)
Overview of Machining Technology	477	(4)
Theory of Chip Formation in Metal Machining	481	(4)
Force Relationships and the Merchant Equation	485	(5)
Power and Energy Relationships in Machining	490	(3)
Cutting Temperature	493	(6)
Machining Operations and Machine Tools	499	(35)
Turning and Related Operations	502	(9)
Drilling and Related Operations	511	(4)
Milling	515	(7)
Machining Centers and Turning Centers	522	(2)
Other Machining Operations	524	(5)
High-Speed Machining	529	(5)
Cutting Tool Technology	534	(31)
Tool Life	534	(7)
Tool Materials	541	(9)
Tool Geometry	550	(8)
Cutting Fluids	558	(7)
Economic And Product Design Considerations In Machining	565	(20)
Machinability	565	(3)
Tolerances and Surface Finish	568	(4)
Selection of Cutting Conditions	572	(6)
Product Design Considerations in Machining	578	(7)
Grinding and Other Abrasive Processes	585	(25)
Grinding	586	(17)
Related Abrasive Process	603	(7)
Nontraditional Machining and Thermal Cutting Processes	610	(29)
Mechanical Energy Processes	611	(4)
Electrochemical Machining Processes	615	(4)
Thermal Energy Processes	619	(8)
Chemical Machining	627	(6)
Application Considerations	633	(6)
Part VII Property Enhancing and Surface Processing Operations
Heat Treatment of Metals	639	(12)
Annealing	640	(1)
Martensite Formation in Steel	640	(4)
Precipitation Hardening	644	(1)
Surface Hardening	645	(2)
Heat Treatment Methods and Facilities	647	(4)
Cleaning and Surface Treatments	651	(8)
Chemical Cleaning	651	(3)
Mechanical Cleaning and Surface Preparation	654	(2)
Diffusion and Ion Implantation	656	(3)
Coating and Deposition Processes	659	(20)
Plating and Related Processes	660	(4)
Conversion Coatings	664	(1)
Physical Vapor Deposition	665	(3)
Chemical Vapor Deposition	668	(3)
Organic Coatings	671	(3)
Porcelain Enameling and Other Ceramic Coatings	674	(1)
Thermal and Mechanical Coating Processes	674	(5)
Part VIII Joining and Assembly Processes
Fundamentals of Welding	679	(15)
Overview of Welding Technology	681	(2)
The Weld Joint	683	(3)
Physics of Welding	686	(4)
Features of a Fusion-Welded Joint	690	(4)
Welding Processes	694	(40)
Arc Welding	695	(10)
Resistance Welding	705	(7)
Oxyfuel Gas Welding	712	(4)
Other Fusion-Welding Processes	716	(3)
Solid-State Welding	719	(5)
Weld Quality	724	(4)
Weldability	728	(1)
Design Considerations in Welding	729	(5)
Brazing, Soldering, and Adhesive Bonding	734	(18)
Brazing	735	(5)
Soldering	740	(4)
Adhesive Bonding	744	(8)
Mechanical Assembly	752	(20)
Threaded Fasteners	753	(6)
Rivets and Eyelets	759	(1)
Assembly Methods based on Interference Fits	760	(3)
Other Mechanical Fastening Methods	763	(2)
Molding Inserts and Integral Fasteners	765	(1)
Design for Assembly	766	(6)
Part IX Special Processing and Assembly Technologies
Rapid Prototyping	772	(14)
Fundamentals of Rapid Prototyping	773	(1)
Rapid Prototyping Technologies	774	(8)
Applications Issues in Rapid Prototyping	782	(4)
Processing of Integrated Circuits	786	(33)
Overview of IC Processing	787	(5)
Silicon Processing	792	(4)
Lithography	796	(4)
Layer Processes Use in IC Fabrication	800	(7)
Integrating the Fabrication Steps	807	(1)
IC Packaging	808	(5)
Yields in IC Processing	813	(6)
Electronics Assembly and Packaging	819	(26)
Electronics Packaging	819	(2)
Printed Circuit Boards	821	(10)
Printed Circuit Board Assembly	831	(4)
Surface Mount Technology	835	(4)
Electrical Connector Technology	839	(6)
Microfabrication Technologies	845	(15)
Microsystem Products	845	(5)
Microfabrication Processes	850	(7)
Nanotechnology	857	(3)
Part X Manufacturing Systems
Numerical Control and Industrial Robotics	860	(24)
Numerical Control	861	(12)
Industrial Robotics	873	(5)
Programmable Logic Controllers	878	(6)
Group Technology and Flexible Manufacturing Systems	884	(12)
Group Technology	884	(5)
Flexible Manufacturing Systems	889	(7)
Production Lines	896	(16)
Fundamentals of Production Lines	896	(4)
Manual Assembly Lines	900	(4)
Automated Production Lines	904	(8)
Part XI Manufacturing Support Systems
Manufacturing Engineering	912	(16)
Process Planning	913	(8)
Problem Solving and Continuous Improvement	921	(1)
Concurrent Engineering and Design for Manufacturability	922	(6)
Production Planning and Control	928	(19)
Aggregate Planning and the Master Production Schedule	930	(1)
Inventory Control	931	(4)
Material and Capacity Requirements Planning	935	(4)
Just-in-Time and Lean Production	939	(3)
Shop Floor Control	942	(5)
Quality Control	947	(18)
What Is Quality?	947	(2)
Process Capability	949	(1)
Statistical Tolerancing	949	(4)
Taguchi Methods	953	(2)
Statistical Process Control	955	(10)
Measurement and Inspection	965	(24)
Metrology	966	(3)
Inspection Principles	969	(2)
Conventional Measuring Instruments and Gages	971	(7)
Measurement of Surfaces	978	(2)
Advanced Measurement and Inspection Technologies	980	(9)
Index	989