Manufacturing Processes for Engineering Materials

by Kalpakjian, Serope; Schmid, Steven R.

• ISBN13: 9780130408716
• ISBN10: 0130408719
• Edition: 4th
• Format: Hardcover
• Copyright: 2003-01-01
• Publisher: Pearson College Div

Summary

"This new edition of Manufacturing Processes for Engineering Materials continues its tradition of balanced and comprehensive coverage of relevant engineering fundamentals, mathematical analysis, and traditional as well as advanced applications of manufacturing processes and operations. Updated and thoroughly edited for improved readability and clarity, this book is written mainly for students in mechanical, industrial, and metallurgical and materials engineering programs. The text continually emphasizes the important interactions among a wide variety of technical disciplines and the economics of manufacturing operations in an increasingly competitive global marketplace."--BOOK JACKET.

Author Biography

Serope Kalpakjian is a professor emeritus of mechanical and materials engineering at the Illinois Institute of Technology.

Table of Contents

Preface	xiii
Introduction	1	(25)
What Is Manufacturing?	1	(5)
Product Design and Concurrent Engineering	6	(2)
Design for Manufacture, Assembly, Disassembly, and Service	8	(2)
Environmentally Conscious Design and Manufacturing	10	(1)
Selecting Materials	11	(3)
Selecting Manufacturing Processes	14	(3)
Computer-Integrated Manufacturing	17	(3)
Quality Assurance and Total Quality Management	20	(1)
Product Liability	21	(1)
Manufacturing Costs, Lean Production, and Agile Manufacturing	22	(1)
General Trends in Manufacturing	23	(1)
Responsibilities of Manufacturing Engineers	24	(2)
Summary	24	(2)
Fundamentals of the Mechanical Behavior of Materials	26	(55)
Introduction	26	(1)
Tension	27	(16)
Compression	43	(3)
Torsion	46	(2)
Bending	48	(1)
Hardness	49	(5)
Fatigue	54	(1)
Creep	55	(1)
Impact	56	(1)
Residual Stresses	57	(3)
Triaxial Stresses and Yield Criteria	60	(8)
Work of Deformation	68	(13)
Summary	72	(2)
Summary of Equations	74	(1)
Bibliography	75	(1)
Questions	75	(2)
Problems	77	(4)
Structure and Manufacturing Properties of Metals	81	(47)
Introduction	81	(1)
The Crystal Structure of Metals	82	(1)
Deformation and Strength of Single Crystals	83	(6)
Grains and Grain Boundaries	89	(3)
Plastic Deformation of Polycrystalline Metals	92	(1)
Recovery, Recrystallization, and Grain Growth	93	(2)
Cold, Warm, and Hot Working	95	(1)
Failure and Fracture	96	(7)
Physical Properties	103	(5)
Properties and Applications of Ferrous Alloys	108	(4)
Properties and Applications of Nonferrous Metals and Alloys	112	(16)
Summary	124	(1)
Summary of Equations	125	(1)
Bibliography	125	(1)
Questions	126	(1)
Problems	127	(1)
Surfaces, Tribology, Dimensional Characteristics, Inspection, and Product Quality Assurance	128	(58)
Introduction	128	(1)
Surface Structure and Properties	129	(1)
Surface Texture	130	(4)
Tribology: Friction, Wear, and Lubrication	134	(17)
Surface Treatments, Coatings, and Cleaning	151	(9)
Engineering Metrology and Instrumentation	160	(5)
Dimensional Tolerances	165	(2)
Testing and Inspection	167	(3)
Quality Assurance	170	(16)
Summary	180	(1)
Summary of Equations	181	(1)
Bibliography	182	(1)
Questions	183	(1)
Problems	184	(1)
Design	185	(1)
Metal-Casting Processes and Equipment; Heat Treatment	186	(74)
Introduction	186	(1)
Solidification of Metals	187	(8)
Cast Structures	195	(4)
Fluid Flow and Heat Transfer	199	(8)
Melting Practice and Furnaces	207	(2)
Casting Alloys	209	(6)
Ingot Casting and Continuous Casting	215	(3)
Casting Processes: Expendable Mold, Permanent Pattern	218	(6)
Casting Processes: Expendable Mold, Expendable Pattern	224	(3)
Casting Processes: Permanent Mold	227	(8)
Heat Treatment	235	(10)
Design Considerations	245	(4)
Economics of Casting	249	(11)
Case Study: Permanent-Mold Casting of Aluminum Automotive Pistons	250	(2)
Summary	252	(1)
Summary of Equations	253	(1)
Bibliography	254	(1)
Questions	254	(2)
Problems	256	(2)
Design	258	(2)
Bulk Deformation Processes	260	(76)
Introduction	260	(1)
Forging	260	(22)
Rolling	282	(18)
Extrusion	300	(12)
Rod, Wire, and Tube Drawing	312	(9)
Swaging	321	(1)
Die Manufacturing Methods	322	(2)
Die Failures	324	(12)
Case Study: Manufacturing Solid Rocket-Motor Case Segments for the Space Shuttle	325	(2)
Summary	327	(1)
Summary of Equations	328	(1)
Bibliography	329	(1)
Questions	330	(2)
Problems	332	(3)
Design	335	(1)
Sheet-Metal Forming Processes	336	(68)
Introduction	336	(1)
Sheet-Metal Characteristics	336	(5)
Shearing	341	(8)
Bending of Flat Sheet and Plate	349	(11)
Stretch Forming	360	(2)
Bulging	362	(1)
Rubber Forming and Hydroforming	363	(1)
Spinning	364	(4)
High-Energy-Rate Forming	368	(3)
Superplastic Forming	371	(1)
Various Forming Methods	372	(2)
Deep Drawing	374	(11)
Formability of Sheet Metals	385	(6)
Equipment for Sheet-Metal Forming	391	(1)
Design Considerations	392	(2)
Economics of Sheet-Metal Forming	394	(10)
Case Study: Can Manufacturing	394	(3)
Summary	397	(2)
Summary of Equations	399	(1)
Bibliography	399	(1)
Questions	400	(1)
Problems	401	(2)
Design	403	(1)
Material-Removal Processes: Cutting	404	(100)
Introduction	404	(1)
Mechanics of Chip Formation	405	(21)
Tool Wear and Failure	426	(8)
Surface Finish and Integrity	434	(3)
Machinability	437	(3)
Cutting-Tool Materials	440	(11)
Cutting Fluids	451	(3)
Cutting Processes and Machine Tools for Producing Round Shapes	454	(14)
Cutting Processes and Machine Tools for Producing Various Shapes	468	(14)
Machining and Turning Centers	482	(4)
Vibration and Chatter	486	(2)
Machine-Tool Structures	488	(1)
Design Considerations	489	(1)
Economics of Machining	490	(14)
Case Study: High-Speed Dry Machining of Cast-Iron Engine Blocks	493	(1)
Summary	494	(2)
Summary of Equations	496	(1)
Bibliography	497	(1)
Questions	498	(3)
Problems	501	(1)
Design	502	(2)
Material Removal Processes: Abrasive, Chemical, Electrical, and High-Energy Beams	504	(55)
Introduction	504	(1)
Abrasives	505	(1)
Bonded Abrasives	506	(4)
Mechanics of Grinding	510	(7)
Grinding-Wheel Wear	517	(4)
Grinding Operations and Machines	521	(6)
Ultrasonic Machining	527	(1)
Finishing Operations	528	(4)
Deburring	532	(1)
Chemical Machining	533	(4)
Electrochemical Machining	537	(2)
Electrochemical Grinding	539	(1)
Electrical-Discharge Machining	540	(4)
High-Energy-Beam Machining	544	(3)
Water-Jet, Abrasive Water-Jet, and Abrasive-Jet Machining	547	(2)
Design Considerations	549	(1)
Process Economics	549	(10)
Case Study: Manufacture of Stents	551	(2)
Summary	553	(1)
Summary of Equations	554	(1)
Bibliography	554	(1)
Questions	555	(2)
Problems	557	(1)
Design	558	(1)
Properties and Processing of Polymers and Reinforced Plastics; Rapid Prototyping and Rapid Tooling	559	(71)
Introduction	559	(1)
The Structure of Polymers	560	(8)
Thermoplastics: Behavior and Properties	568	(7)
Thermosets: Behavior and Properties	575	(1)
Thermoplastics: General Characteristics and Applications	576	(2)
Thermosets: General Characteristics and Applications	578	(1)
High-Temperature Polymers, Electrically Conducting Polymers, and Biodegradable Plastics	579	(2)
Elastomers (Rubbers): General Characteristics and Applications	581	(1)
Reinforced Plastics	582	(8)
Processing of Plastics	590	(15)
Processing of Polymer-Matrix-Reinforced Plastics	605	(5)
Rapid Prototyping and Rapid Tooling	610	(9)
Design Considerations	619	(2)
Economics of Processing Plastics	621	(9)
Case Study: The EPOCH Hip	622	(1)
Summary	623	(1)
Summary of Equations	624	(1)
Bibliography	625	(1)
Questions	626	(2)
Problems	628	(1)
Design	629	(1)
Properties and Processing of Metal Powders, Ceramics, Glasses, Composites, and Superconductors	630	(58)
Introduction	630	(1)
Production of Metal Powders	631	(5)
Compaction of Metal Powders	636	(8)
Sintering	644	(5)
Secondary and Finishing Operations	649	(2)
Design Considerations for Powder Metallurgy	651	(2)
Economics of Powder Metallurgy	653	(2)
Ceramics: Structure, Properties, and Applications	655	(8)
Shaping Ceramics	663	(5)
Glasses: Structure, Properties, and Applications	668	(3)
Forming and Shaping Glass	671	(4)
Design Considerations for Ceramics and Glasses	675	(1)
Graphite and Diamond	675	(1)
Processing Metal-Matrix and Ceramic-Matrix Composites	676	(3)
Processing Superconductors	679	(9)
Case Study: Production of High-Temperature Superconducting Tapes	679	(3)
Summary	682	(1)
Summary of Equations	683	(1)
Bibliography	683	(2)
Questions	685	(1)
Problems	686	(1)
Design	687	(1)
Joining and Fastening Processes	688	(65)
Introduction	688	(2)
Arc-Welding Processes: Consumable Electrode	690	(7)
Arc-Welding Processes: Nonconsumable Electrode	697	(2)
High-Energy-Beam Welding	699	(2)
The Fusion-Welded Joint	701	(11)
Cold Welding	712	(1)
Ultrasonic Welding	713	(1)
Friction Welding	714	(2)
Resistance Welding	716	(5)
Explosion Welding	721	(1)
Diffusion Bonding	722	(1)
Brazing and Soldering	723	(7)
Adhesive Bonding	730	(4)
Mechanical Fastening	734	(3)
Joining Plastics, Ceramics, and Glasses	737	(3)
Design Considerations in Joining	740	(3)
Economic Considerations	743	(10)
Case Study: Light-Curing Acrylic Adhesives for Medical Products	744	(2)
Summary	746	(1)
Bibliography	747	(2)
Questions	749	(2)
Problems	751	(1)
Design	752	(1)
Fabrication of Microelectronic and Micromechanical Devices	753	(55)
Introduction	753	(3)
Semiconductors and Silicon	756	(1)
Crystal Growing and Wafer Preparation	757	(2)
Films and Film Deposition	759	(2)
Oxidation	761	(1)
Lithography	762	(3)
Diffusion and Ion Implantation	765	(1)
Etching	766	(10)
Metallization and Testing	776	(2)
Wire Bonding and Packaging	778	(3)
Yield and Reliability of Chips	781	(1)
Printed Circuit Boards	782	(3)
Micromachining of MEMS Devices	785	(9)
The LIGA Microfabrication Process	794	(5)
Solid Free-Form Fabrication of Devices	799	(9)
Case Study: Accelerometer for Automotive Air Bags	800	(3)
Summary	803	(1)
Bibliography	804	(1)
Questions	805	(1)
Problems	806	(1)
Design	806	(2)
Automation of Manufacturing Processes and Systems	808	(44)
Introduction	808	(1)
Automation	809	(6)
Numerical Control	815	(6)
Programming for Numerical Control	821	(1)
Adaptive Control	822	(3)
Material Handling and Movement	825	(2)
Industrial Robots	827	(6)
Sensor Technology	833	(4)
Flexible Fixturing	837	(2)
Assembly, Disassembly, and Service	839	(3)
Design Considerations	842	(3)
Economic Considerations	845	(7)
Case Study: Development of a Modular Fixture	845	(2)
Summary	847	(1)
Bibliography	848	(1)
Questions	849	(1)
Design	850	(2)
Computer-Integrated Manufacturing Systems	852	(41)
Introduction	852	(1)
Manufacturing Systems	853	(1)
Computer-Integrated Manufacturing	854	(2)
Computer-Aided Design and Engineering	856	(5)
Computer-Aided Manufacturing	861	(1)
Computer-Aided Process Planning	861	(3)
Computer Simulation of Manufacturing Processes and Systems	864	(2)
Group Technology	866	(6)
Cellular Manufacturing	872	(2)
Flexible Manufacturing Systems	874	(2)
Just-in-Time Production	876	(2)
Communications Networks in Manufacturing	878	(2)
Artificial Intelligence	880	(3)
The Factory of the Future	883	(2)
Economic Considerations	885	(8)
Case Study: CAD Model Development for Automotive Components	886	(3)
Summary	889	(1)
Bibliography	890	(1)
Questions	891	(1)
Design	892	(1)
Product Design and Competitive Aspects of Manufacturing	893	(35)
Introduction	893	(1)
Product Design and Robust Design	894	(4)
Product Quality and Life Expectancy	898	(1)
Life-Cycle Assessment, Life-Cycle Engineering, and Sustainable Manufacturing	899	(2)
Selection of Materials for Products	901	(4)
Substitution of Materials in Products	905	(2)
Capabilities of Manufacturing Processes	907	(4)
Selection of Manufacturing Processes	911	(4)
Manufacturing Costs and Cost Reduction	915	(4)
Value Analysis	919	(9)
Case Study Concurrent Engineering for Intravenous Solution Containers	920	(2)
Summary	922	(1)
Bibliography	923	(1)
Questions	924	(1)
Design	925	(3)
Index	928

Excerpts

The fourth edition of this text, like the previous editions, continues to make an attempt at presenting a comprehensive, balanced, and up-to-date coverage of the relevant fundamentals and real-world applications of engineering materials and manufacturing processes and systems and the analytical approaches involved. The topics covered throughout the 16 chapters reflect the rapid and significant advances that have taken place in various areas in manufacturing, and they are organized and described in such a manner to draw the interest of students. The case studies, mostly from industry, make the subject of manufacturing science arr4engineering less abstract by showing students the practical aspects of process applications. Integration of product design and manufacturing has justly resulted in greater recognition and prestige for these disciplines, and this edition therefore puts greater emphasis and better focus on this increasingly important subject. While studying this text, students should be able to assess the capabilities, limitations, and potential of production processes, including, particularly, the processes' economic and competitive aspects. The discussions throughout the chapters are aimed at motivating and challenging students to explore technically and economically viable solutions to a wide variety of important questions and problems in product design and manufacturing. This book has been written mainly for undergraduate students in mechanical, industrial, and metallurgical and materials engineering programs; it is also useful for graduate courses in manufacturing science and engineering. The text, as well as the numerous examples and case studies in each chapter, clearly shows that manufacturing engineering is an interdisciplinary and complex subject and that it is as important, exciting, and challenging as any other engineering discipline. What's new in this edition A new chapter has been added that covers the fabrication of microelectronic and micromechanical devices. The discussion of design considerations in each chapter have been expanded. Several new examples and case studies have been added throughout all chapters. A total of 1230 questions and problems has been added-30% more than in the third edition. Questions and problems now include a total of 140 design problems. Figures have been improved for better graphical impact. More cross-references to sections and chapters have been added throughout the text. All chapter bibliographies have been thoroughly updated. New or expanded topics for this edition include the following: Automated guided vehicles Biodegradable plastics Cryogenic machining and grinding Cryogenic treatment of cutting tools Design considerations for casting Design considerations for powder metallurgy Design considerations for sheet-metal forming Electrically conducting adhesives Enterprise resource planning Flexible fixturing ISO 9000 and 14000 standards Life-cycle assessment LIGA process Metal foams Microelectromechanical systems fabrication Microelectronics device fabrication Micromachining Modeling of casting Nanomaterials Plasma and wet etching Polymer processing Printed circuit boards Rapid protoyping and rapid tooling Rotary ultrasonic machining Silicon microstructure Six-sigma quality Solid free-form fabrication Stick-slip in extrusion Superconductor processing Surface-mount technology Value assessment Vibration and chatter in rolling Water-jet peening