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Book SynopsisTable of ContentsContent available in eBook
Student solution available in interactive e-text
1 Introduction and Overview of Manufacturing 1
1.1 What Is Manufacturing? 2
1.2 Materials in Manufacturing 8
1.3 Manufacturing Processes 10
1.4 Production Systems 17
1.5 Manufacturing Economics 20
Part I Material Properties and Product Attributes 27
2 The Nature of Materials 27
2.1 Atomic Structure and the Elements 27
2.2 Bonding between Atoms and Molecules 30
2.3 Crystalline Structures 32
2.4 Noncrystalline (Amorphous) Structures 37
2.5 Engineering Materials 38
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 64
4.1 Volumetric and Melting Properties 64
4.2 Thermal Properties 67
4.3 Mass Diffusion 69
4.4 Electrical Properties 71
4.5 Electrochemical Processes 73
5 Dimensions, Surfaces, and Their Measurement 75
5.1 Dimensions, Tolerances, and Related Attributes 75
5.2 Conventional Measuring Instruments and Gages 76
5.3 Surfaces 84
5.4 Measurement of Surfaces 88
5.5 Effect of Manufacturing Processes 90
Part II Engineering Materials 93
6 Metals 93
6.1 Alloys and Phase Diagrams 94
6.2 Ferrous Metals 98
6.3 Nonferrous Metals 114
6.4 Superalloys 124
7 Ceramics 126
7.1 Structure and Properties of Ceramics 127
7.2 Traditional Ceramics 129
7.3 New Ceramics 131
7.4 Glass 134
7.5 Some Important Elements Related to Ceramics 138
8 Polymers 142
8.1 Fundamentals of Polymer Science and Technology 144
8.2 Thermoplastic Polymers 153
8.3 Thermosetting Polymers 157
8.4 Elastomers 160
8.5 Polymer Recycling and Biodegradability 166
9 Composite Materials 169
9.1 Technology and Classification of Composite Materials 170
9.2 Metal Matrix Composites 177
9.3 Ceramic Matrix Composites 179
9.4 Polymer Matrix Composites 180
Part III Solidification Processes 184
10 Fundamentals of Metal Casting 184
10.1 Overview of Casting Technology 186
10.2 Heating and Pouring 188
10.3 Solidification and Cooling 192
11 Metal Casting Processes 200
11.1 Sand Casting 200
11.2 Other Expendable-Mold Casting Processes 204
11.3 Permanent-Mold Casting Processes 209
11.4 Foundry Practice 218
11.5 Casting Quality 222
11.6 Castability and Casting Economics 224
11.7 Product Design Considerations 229
12 Glassworking 232
12.1 Raw Materials Preparation and Melting 232
12.2 Shaping Processes in Glassworking 233
12.3 Heat Treatment and Finishing 239
12.4 Product Design Considerations 240
13 Shaping Processes For Plastics 242
13.1 Properties of Polymer Melts 243
13.2 Extrusion 245
13.3 Production of Sheet and Film 257
13.4 Fiber and Filament Production (Spinning) 260
13.5 Coating Processes 261
13.6 Injection Molding 262
13.7 Compression and Transfer Molding 275
13.8 Blow Molding and Rotational Molding 277
13.9 Thermoforming 282
13.10 Casting 286
13.11 Polymer Foam Processing and Forming 287
13.12 Product Design Considerations 288
14 Processing of Polymer Matrix Composites and Rubber 291
14.1 Overview of PMC Processing 291
14.2 Open-Mold Processes 295
14.3 Closed-Mold Processes 299
14.4 Other PMC Shaping Processes 301
14.5 Rubber Processing and Shaping 305
14.6 Manufacture of Tires and Other Rubber Products 310
Part IV Particulate Processing of Metals and Ceramics 315
15 Powder Metallurgy 315
15.1 Characterization of Engineering Powders 317
15.2 Production of Metallic Powders 321
15.3 Conventional Pressing and Sintering 323
15.4 Alternative Pressing and Sintering Techniques 329
15.5 Powder Metallurgy Materials and Economics 331
15.6 Product Design Considerations in Powder Metallurgy 334
16 Processing of Ceramics and Cermets 338
16.1 Processing of Traditional Ceramics 338
16.2 Processing of New Ceramics 345
16.3 Processing of Cermets 348
16.4 Product Design Considerations 350
Part V Metal Forming and Sheet Metalworking 352
17 Fundamentals of Metal Forming 352
17.1 Overview of Metal Forming 352
17.2 Material Behavior in Metal Forming 355
17.3 Temperature in Metal Forming 356
17.4 Strain Rate Sensitivity 358
17.5 Friction and Lubrication in Metal Forming 360
18 Bulk Deformation Processes In Metal Working 362
18.1 Rolling 362
18.2 Forging 372
18.3 Extrusion 387
18.4 Wire and Bar Drawing 397
19 Sheet Metalworking 405
19.1 Cutting Operations 406
19.2 Bending Operations 412
19.3 Drawing 416
19.4 Equipment and Economics for Sheet-Metal Pressworking 423
19.5 Other Sheet-Metal-Forming Operations 432
19.6 Sheet-Metal Operations Not Performed on Presses 435
19.7 Bending of Tube Stock 440
Part VI Material Removal Processes 443
20 Theory of Metal Machining 443
20.1 Overview of Machining Technology 445
20.2 Theory of Chip Formation in Metal Machining 448
20.3 Force Relationships and the Merchant Equation 452
20.4 Power and Energy Relationships in Machining 458
20.5 Cutting Temperature 460
21 Machining Operations and Machine Tools 463
21.1 Machining and Part Geometry 463
21.2 Turning and Related Operations 466
21.3 Drilling and Related Operations 475
21.4 Milling 479
21.5 Machining Centers and Turning Centers 487
21.6 Other Machining Operations 489
21.7 Machining Operations for Special Geometries 494
21.8 High-Speed Machining 500
22 Cutting-Tool Technology 503
22.1 Tool Life 503
22.2 Tool Materials 509
22.3 Tool Geometry 517
22.4 Cutting Fluids 526
23 Economic and Product Design Considerations In Machining 530
23.1 Machinability 530
23.2 Tolerances and Surface Finish 531
23.3 Machining Economics 536
23.4 Product Design Considerations in Machining 543
24 Grinding and Other Abrasive Processes 546
24.1 Grinding 547
24.2 Related Abrasive Processes 562
25 Nontraditional Machining and Thermal Cutting Processes 567
25.1 Mechanical Energy Processes 568
25.2 Electrochemical Machining Processes 571
25.3 Thermal Energy Processes 575
25.4 Chemical Machining 584
25.5 Application Considerations 589
Part VII Property Enhancing and Surface Processing Operations 592
26 Heat Treatment of Metals 592
26.1 Annealing 592
26.2 Martensite Formation in Steel 593
26.3 Precipitation Hardening 597
26.4 Surface Hardening 598
26.5 Heat Treatment Methods and Facilities 599
27 Surface Processing Operations 602
27.1 Industrial Cleaning Processes 602
27.2 Diffusion and Ion Implantation 606
27.3 Plating and Related Processes 607
27.4 Conversion Coating 611
27.5 Vapor Deposition Processes 612
27.6 Organic Coatings 618
27.7 Porcelain Enameling and Other Ceramic Coatings 620
27.8 Thermal and Mechanical Coating Processes 621
Part VIII Joining and Assembly Processes 623
28 Fundamentals of Welding 623
28.1 Overview of Welding Technology 624
28.2 The Weld Joint 627
28.3 Physics of Welding 629
28.4 Features of a Fusion-Welded Joint 633
29 Welding Processes 635
29.1 Arc Welding 635
29.2 Resistance Welding 644
29.3 Oxyfuel Gas Welding 651
29.4 Other Fusion-Welding Processes 655
29.5 Solid-State Welding 657
29.6 Weld Quality 663
29.7 Weldability and Welding Economics 667
29.8 Design Considerations in Welding 670
30 Brazing, Soldering, and Adhesive Bonding 672
30.1 Brazing 672
30.2 Soldering 677
30.3 Adhesive Bonding 681
31 Mechanical Assembly 687
31.1 Threaded Fasteners 687
31.2 Rivets and Eyelets 694
31.3 Assembly Methods Based on Interference Fits 695
31.4 Other Mechanical Fastening Methods 698
31.5 Molding Inserts and Integral Fasteners 699
31.6 Design for Assembly 700
Part IX Special Processing and Assembly Technologies (Available in e-text for students) W-1
32 Additive Manufacturing W-1
(Available in e-text for students)
33 Processing of Integrated Circuits W-21
(Available in e-text for students)
34 Electronics Assembly and Packaging W-50
(Available in e-text for students)
35 Microfabrication Technologies W-71
(Available in e-text for students)
36 Nanofabrication Technologies W-83
(Available in e-text for students)
Part X Manufacturing Systems (Available in e-text for students) W-97
37 Automation Technologies For Manufacturing Systems W-97
(Available in e-text for students)
38 Integrated Manufacturing Systems W-122
(Available in e-text for students)
Part XI Manufacturing Support Systems W-144
39 Process Planning and Production Control W-144
(Available in e-text for students)
40 Quality Control and Inspection W-170
(Available in e-text for students)
Review Questions and Problems P-1
Index I-1
