Description
Book SynopsisNewly revised,
DeGarmo''s Materials and Processes in Manufacturing has been the market-leading text on manufacturing and manufacturing processes courses for over fifty years. Authors J T. Black and Ron Kohser have continued this book''s long and distinguished tradition of exceedingly clear presentation and highly practical approach to materials and processes, presenting mathematical models and analytical equations only when they enhance the basic understanding of the material. Updated to reflect all current practices, standards, and materials, this edition has new coverage of additive manufacturing, lean engineering, and processes related to ceramics, polymers, and plastics.
Table of ContentsPreface iii
1 Introduction to DeGarmo’s Materials and Processes in Manufacturing 1
1.1 Materials, Manufacturing, and the Standard of Living 1
1.2 Manufacturing and Production Systems 3
Review Questions 24
Problems 25
2 Properties of Materials 26
2.1 Introduction 26
2.2 Static Properties 28
2.3 Dynamic Properties 38
2.4 Temperature Effects (Both High and Low) 43
2.5 Machinability, Formability, and Weldability 46
2.6 Fracture Toughness and the Fracture Mechanics Approach 46
2.7 Physical Properties 48
2.8 Testing Standards and Testing Concerns 48
Review Questions 48
Problems 50
3 Nature of Materials 51
3.1 Structure—Property—Processing—Performance Relationships 51
3.2 The Structure of Atoms 52
3.3 Atomic Bonding 52
3.4 Secondary Bonds 53
3.5 Atom Arrangements in Materials 54
3.6 Crystal Structures 54
3.7 Development of a Grain Structure 56
3.8 Elastic Deformation 56
3.9 Plastic Deformation 57
3.10 Dislocation Theory of Slippage 58
3.11 Strain Hardening or Work Hardening 59
3.12 Plastic Deformation in Polycrystalline Material 60
3.13 Grain Shape and Anisotropic Properties 60
3.14 Fracture 61
3.15 Cold Working, Recrystallization, and Hot Working 61
3.16 Grain Growth 62
3.17 Alloys and Alloy Types 62
3.18 Atomic Structure and Electrical Properties 62
Review Questions 63
Problems 64
4 Equilibrium Phase Diagrams and the Iron–Carbon System 65
4.1 Introduction 65
4.2 Phases 65
4.3 Equilibrium Phase Diagrams 65
4.4 Iron–Carbon Equilibrium Diagram 71
4.5 Steels and the Simplified Iron–Carbon Diagram 72
4.6 Cast Irons 74
Review Questions 75
Problems 76
5 Heat Treatment 77
5.1 Introduction 77
5.2 Processing Heat Treatments 77
5.3 Heat Treatments Used to Increase Strength 80
5.4 Strengthening Heat Treatments for Nonferrous Metals 80
5.5 Strengthening Heat Treatments for Steel 83
5.6 Surface Hardening of Steel 94
5.7 Furnaces 96
5.8 Heat Treatment and Energy 97
Review Questions 98
Problems 99
6 Ferrous Metals and Alloys 101
6.1 Introduction to History-Dependent Materials 101
6.2 Ferrous Metals 101
6.3 Iron 102
6.4 Steel 102
6.5 Stainless Steels 113
6.6 Tool Steels 115
6.7 Cast Irons 117
6.8 Cast Steels 120
6.9 The Role of Processing on Cast Properties 120
Review Questions 121
Problems 122
7 Nonferrous Metals and Alloys 123
7.1 Introduction 123
7.2 Copper and Copper Alloys 123
7.3 Aluminum and Aluminum Alloys 128
7.4 Magnesium and Magnesium Alloys 134
7.5 Zinc and Zinc Alloys 136
7.6 Titanium and Titanium Alloys 137
7.7 Nickel-Based Alloys 138
7.8 Superalloys, Refractory Metals, and Other Materials Designed for High-Temperature Service 138
7.9 Lead and Tin and Their Alloys 141
7.10 Some Lesser-Known Metals and Alloys 141
7.11 Metallic Glasses 141
7.12 Graphite 142
7.13 Materials for Specific Applications 142
7.14 High Entropy Alloys 142
Review Questions 143
Problems 144
8 Nonmetallic Materials: Plastics, Elastomers, Ceramics, and Composites 145
8.1 Introduction 145
8.2 Plastics 145
8.3 Elastomers 156
8.4 Ceramics 159
8.5 Composite Materials 166
Review Questions 174
Problems 175
9 Material Selection 177
9.1 Introduction 177
9.2 Material Selection and Manufacturing Processes 179
9.3 The Design Process 179
9.4 Approaches to Material Selection 180
9.5 Additional Factors to Consider 183
9.6 Consideration of the Manufacturing Process 183
9.7 Ultimate Objective 184
9.8 Materials Substitution 185
9.9 Effect of Product Liability on Materials Selection 186
9.10 Aids to Material Selection 186
Review Questions 187
Problems 188
10 Fundamentals of Casting 191
10.1 Introduction to Materials Processing 191
10.2 Introduction to Casting 192
10.3 Casting Terminology 193
10.4 The Solidification Process 194
10.5 Patterns 202
10.6 Design Considerations in Castings 203
10.7 The Casting Industry 206
Review Questions 206
Problems 208
11 Expendable-Mold Casting Processes 209
11.1 Introduction 209
11.2 Sand Casting 209
11.3 Cores and Core Making 222
11.4 Other Expendable-Mold Processes with Multiple-Use Patterns 225
11.5 Expendable-Mold Processes Using Single-Use Patterns 226
11.6 Shakeout, Cleaning, and Finishing 232
11.7 Summary 232
Review Questions 232
Problems 234
12 Multiple-Use-Mold Casting Processes 235
12.1 Introduction 235
12.2 Permanent-Mold Casting 235
12.3 Die Casting 238
12.4 Squeeze Casting and Semisolid Casting 241
12.5 Centrifugal Casting 242
12.6 Continuous Casting 244
12.7 Melting 244
12.8 Pouring Practice 247
12.9 Cleaning, Finishing, Heat Treating, and Inspection 247
12.10 Automation in Foundry Operations 248
12.11 Process Selection 248
Review Questions 250
Problems 251
13 Fabrication of Plastics, Ceramics, and Composites 252
13.1 Introduction 252
13.2 Fabrication of Plastics 252
13.3 Processing of Rubber and Elastomers 262
13.4 Processing of Ceramics 263
13.5 Fabrication of Composite Materials 267
Review Questions 275
Problems 277
14 Fundamentals of Metal Forming 279
14.1 Introduction 279
14.2 Forming Processes: Independent Variables 280
14.3 Dependent Variables 281
14.4 Independent–Dependent Relationships 281
14.5 Process Modeling 282
14.6 General Parameters 282
14.7 Friction, Lubrication, and Wear under Metalworking Conditions 283
14.8 Temperature Concerns 284
14.9 Formability 290
Review Questions 290
Problems 292
15 Bulk Forming Processes 293
15.1 Introduction 293
15.2 Classification of Deformation Processes 293
15.3 Bulk Deformation Processes 294
15.4 Rolling 294
15.5 Forging 298
15.6 Extrusion 308
15.7 Wire, Rod, and Tube Drawing 312
15.8 Cold Forming, Cold Forging, and Impact Extrusion 314
15.9 Piercing 317
15.10 Other Squeezing Processes 318
15.11 Surface Improvement by Deformation Processing 320
Review Questions 321
Problems 322
16 Sheet-Forming Processes 325
16.1 Introduction 325
16.2 Shearing Operations 325
16.3 Bending 331
16.4 Drawing and Stretching Processes 338
16.5 Alternative Methods of Producing Sheet-Type Products 349
16.6 Seamed Pipe Manufacture 349
16.7 Presses 350
Review Questions 354
Problems 356
17 Powder Metallurgy (Particulate Processing) 357
17.1 Introduction 357
17.2 The Basic Process 357
17.3 Powder Manufacture 358
17.4 Powder Testing and Evaluation 359
17.5 Powder Mixing and Blending 360
17.6 Compacting 360
17.7 Sintering 363
17.8 Advances in Sintering (Shorter Time, Higher Density, Stronger Products) 364
17.9 Hot-Isostatic Pressing 365
17.10 Other Techniques to Produce High-Density P/M Products 366
17.11 Metal Injection Molding (MIM) 366
17.12 Secondary Operations 368
17.13 Properties of P/M Products 369
17.14 Design of Powder Metallurgy Parts 371
17.15 Powder Metallurgy Products 371
17.16 Advantages and Disadvantages of Powder Metallurgy 373
17.17 Process Summary 374
Review Questions 375
Problems 376
18 Additive Processes—Including 3-D Printing 377
18.1 Introduction 377
18.2 Layerwise Manufacturing 378
18.3 Liquid-Based Processes 381
18.4 Powder-Based Processes 383
18.5 Deposition-Based Processes 387
18.6 Uses and Applications 390
18.7 Pros, Cons and Current and Future Trends 393
18.8 Economic Considerations 395
Review Questions 396
Problems 397
19 Fundamentals of Machining/ Orthogonal Machining 398
19.1 Introduction 398
19.2 Fundamentals 398
19.3 Forces and Power in Machining 406
19.4 Orthogonal Machining (Two Forces) 409
19.5 Chip Thickness Ratio, rc 412
19.6 Mechanics of Machining (Statics) 413
19.7 Shear Strain, γ, and Shear Front Angle, ϕ 414
19.8 Mechanics of Machining (Dynamics) (Section courtsey of Dr. Elliot Stern) 416
Review Questions 422
Problems 423
20 Cutting Tool Materials 424
20.1 Introduction 424
20.2 Cutting Tool Materials 428
20.3 Tool Geometry 437
20.4 Tool-Coating Processes 438
20.5 Tool Failure and Tool Life 440
20.6 Taylor Tool Life 441
20.7 Cutting Fluids 446
20.8 Economics of Machining 446
Review Questions 448
Problems 449
21 Turning and Boring Processes 451
21.1 Introduction 451
21.2 Fundamentals of Turning, Boring, and Facing Turning 453
21.3 Lathe Design and Terminology 457
21.4 Cutting Tools for Lathes 462
21.5 Workholding in Lathes 466
Review Questions 470
Problems 471
22 Milling 472
22.1 Introduction 472
22.2 Fundamentals of Milling Processes 472
22.3 Milling Tools and Cutters 479
22.4 Machines for Milling 483
Review Questions 487
Problems 487
23 Drilling and Related Hole-Making Processes 488
23.1 Introduction 488
23.2 Fundamentals of the Drilling Process 489
23.3 Types of Drills 490
23.4 Tool Holders for Drills 500
23.5 Workholding for Drilling 501
23.6 Machine Tools for Drilling 501
23.7 Cutting Fluids for Drilling 504
23.8 Counterboring, Countersinking, and Spot Facing 506
23.9 Reaming 506
Review Questions 508
Problems 509
24 Sawing, Broaching, Shaping, and Filing Machining Processes 510
24.1 Introduction 510
24.2 Introduction to Sawing 510
24.3 Introduction to Broaching 518
24.4 Fundamentals of Broaching 520
24.5 Broaching Machines 525
24.6 Introduction to Shaping and Planing 525
24.7 Introduction to Filing 529
Review Questions 531
Problems 532
25 Abrasive Machining Processes 533
25.1 Introduction 533
25.2 Abrasives 535
25.3 Grinding Wheel Structure and Grade 538
25.4 Grinding Wheel Identification 542
25.5 Grinding Machines 546
25.6 Honing 553
25.7 Superfinishing 554
25.8 Free Abrasives 555
25.9 Design Considerations in Grinding 559
Review Questions 559
Problems 560
26 CNC Processes and Adaptive Control: A(4) and A(5) Levels of Automation 561
26.1 Introduction 561
26.2 Basic Principles of Numerical Control 561
26.3 CNC Part Programming 567
26.4 Interpolation and Adaptive Control 574
26.5 Machining Center Features and Trends 577
26.6 Summary 581
Review Questions 581
Problems 582
27 JIG and Fixture Design 584
27.1 Introduction 584
27.2 Conventional Fixture Design 584
27.3 Tool Design Steps 587
27.4 Clamping Considerations 588
27.5 Chip Disposal 589
27.6 Example of Jig Design 589
27.7 Types of Jigs 591
27.8 Conventional Fixtures 593
27.9 Modular Fixturing 593
27.10 Setup and Changeover 594
27.11 Clamps 599
27.12 Other Workholding Devices 599
27.13 Economic Justification of Jigs and Fixtures 602
Review Questions 603
Problems 603
28 Nontraditional Manufacturing Processes 605
28.1 Introduction 605
28.2 Chemical Machining Processes 607
28.3 Electrochemical Machining Processes 611
28.4 Electrical Discharge Machining 616
Review Questions 624
29 Fundamentals of Joining 626
29.1 Introduction to Consolidation Processes 626
29.2 Classification of Welding and Thermal Cutting Processes 627
29.3 Some Common Concerns 627
29.4 Types of Fusion Welds and Types of Joints 628
29.5 Design Considerations 630
29.6 Heat Effects 630
29.7 Weldability or Joinability 635
29.8 Summary 635
Review Questions 636
Problems 637
30 Gas Flame and Arc Processes 638
30.1 Oxyfuel-Gas Welding 638
30.2 Oxygen Torch Cutting 641
30.3 Flame Straightening 643
30.4 Arc Welding 643
30.5 Consumable-Electrode Arc Welding 644
30.6 Nonconsumable Electrode Arc Welding 650
30.7 Other Processes Involving Arcs 654
30.8 Arc Cutting 656
30.9 Metallurgical and Heat Effects in Thermal Cutting 658
30.10 Welding Equipment 658
30.11 Thermal Deburring 659
Review Questions 660
Problems 662
31 Resistance and Solid-State Welding Processes 663
31.1 Introduction 663
31.2 Theory of Resistance Welding 663
31.3 Resistance Welding Processes 665
31.4 Advantages and Limitations of Resistance Welding 669
31.5 Solid-State Welding Processes 669
Review Questions 677
Problems 678
32 Other Welding Processes, Brazing, and Soldering 679
32.1 Introduction 679
32.2 Other Welding and Cutting Processes 679
32.3 Surface Modification by Welding-Related Processes 686
32.4 Brazing 689
32.5 Soldering 696
Review Questions 699
Problems 700
33 Adhesive Bonding, Mechanical Fastening, and Joining of Non-Metals 701
33.1 Adhesive Bonding 701
33.2 Mechanical Fastening 708
33.3 Joining of Plastics 711
33.4 Joining of Ceramics and Glass 713
33.5 Joining of Composites 714
Review Questions 714
Problems 715
34 Surface Integrity and Finishing Processes 717
34.1 Introduction 717
34.2 Surface Integrity 717
34.3 Abrasive Cleaning and Finishing 724
34.4 Chemical Cleaning 729
34.5 Coatings 730
34.6 Vaporized Metal Coatings 738
34.7 Clad Materials 738
34.8 Textured Surfaces 738
34.9 Coil-Coated Sheets 738
34.10 Edge Finishing and Burr Removal 739
Review Questions 741
35 Nano and Micro-Manufacturing Processes 742
35.1 Introduction 742
35.2 Lithography 745
35.3 Micromachining Processes 748
35.4 Deposition Processes 751
35.5 How ICs are Made 757
35.6 Nano- and Micro-Scale Metrology 763
Review Questions 765
Problems 766
36 Measurement and Inspection 767
(online at www.wiley.com/college/black)
36.1 Introduction 767
36.2 Standards of Measurement 767
36.3 Allowance and Tolerance 770
36.4 Inspection Methods for Measurement 776
36.5 Measuring Instruments 777
36.6 Vision Systems 784
36.7 Coordinate Measuring Machines 785
36.8 Angle-measuring Instruments 787
36.9 Gages for Attributes Measuring 787
Review Questions 790
Problems 791
37 Nondestructive Examination (NDE) / Nondestructive Testing (NDT) 793
(online at www.wiley.com/college/black)
37.1 Destructive vs. Nondestructive Testing 793
37.2 Visual Inspection 795
37.3 Liquid Penetrant Inspection 795
37.4 Magnetic Particle Inspection 796
37.5 Ultrasonic Inspection 797
37.6 Radiography 799
37.7 Eddy-Current Testing 800
37.8 Acoustic Emission Monitoring 802
37.9 Other Methods of Nondestructive Testing and Inspection 803
37.10 Dormant vs. Critical Flaws 804
37.11 Current and Future Trends 804
Review Questions 804
Problems 805
38 Manufacturing Automation and Industrial Robots 807
(online at www.wiley.com/college/black)
38.1 Introduction 807
38.2 The A(4) Level of Automation 812
38.3 A(5) Level of Automation Requires Evaluation 818
38.4 Industrial Robotics 822
38.5 Computer-Integrated Manufacturing (CIM) 828
38.6 Computer-Aided Design 830
38.7 Computer-Aided Manufacturing 832
38.8 Summary 832
Review Questions 833
Advanced Topic 1 Process Capability and Quality Control 834
(online at www.wiley.com/college/black)
A1.1 Introduction 834
A1.2 Determining Process Capability 835
A1.3 Introduction to Statistical Quality Control 841
A1.4 Sampling Errors 845
A1.5 Gage Capability 846
A1.6 Just in Time/Total Quality Control 846
A1.7 Six Sigma 855
A1.8 Summary 858
Review Questions 858
Problems 859
Advanced Topic 2 The Enterprise (Production System) 861
(online at www.wiley.com/college/black)
A2.1 Introduction 861
A2.2 Typical Functional Areas in the Production System (PS) 861
Review Questions 876
Problems 877
Advanced Topic 3 Lean Engineering 878
(online at www.wiley.com/college/black)
A3.1 Introduction 878
A3.2 The Lean Engineer 878
A3.3 The Lean Production System 879
A3.4 Linked-Cell Manufacturing System Design Rules 879
A3.5 Manufacturing System Designs 880
A3.6 Preliminary Steps to Lean Production 881
A3.7 Methodology for Implementation of Lean Production 882
A3.8 Design Rule MT < CT 894
A3.9 Decouplers 895
A3.10 Integrating Production Control 898
A3.11 Integrating Inventory Control 900
A3.12 Lean Manufacturing Cell Design 901
A3.13 Machine Tool Design for Lean Manufacturing Cells 904
A3.14 L-CMS Strategy 908
Review Questions 909
Problems 910
Advanced Topic 4 Mixed-Model Final Assembly 911
(online at www.wiley.com/college/black)
A4.1 Introduction 911
A4.2 History 911
A4.3 Mixed-Model Final Assembly 912
A4.4 An Example of MMFA 913
A4.5 Key Enabling Systems 913
A4.6 Manual Assembly Line Balancing 915
A4.7 Sequencing 917
A4.8 Quality in Mixed-Model Final Assembly 918
A4.9 Examples of Assembly Aids/Poka-Yoke(Error-Proofing) Applications 920
Review Questions 921
Problems 922
Index I1
Selected References For Additional Study S1
