Fundamentals of Modern Manufacturing
Materials, Processes, and Systems
5th Edition
Published on 24. September 2012
Book
Hardback
1128 pages
978-1-118-23146-3 (ISBN)
Description
Fundamentals of Modern Manufacturing: Materials, Processes, and Systems, 5th Edition, is designed for a first course or two-course sequence in Manufacturing at the junior level in Mechanical, Industrial, and Manufacturing Engineering curricula. Given its coverage of engineering materials, it is also be suitable for Materials Science and Engineering courses that emphasize Materials Processing. In addition, it may be appropriate for technology programs related to the preceding engineering disciplines. Most of the book's content focuses on Manufacturing Processes (about 65% of the text), but it also covers Engineering Materials and Production Systems.
More details
Edition
5th edition
Language
English
Place of publication
New York
United States
Target group
Professional and scholarly
Dimensions
Height: 257 mm
Width: 201 mm
Thickness: 43 mm
Weight
2087 gr
ISBN-13
978-1-118-23146-3 (9781118231463)
Copyright in bibliographic data and cover images is held by Nielsen Book Services Limited or by the publishers or by their respective licensors: all rights reserved.
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Content
1 INTRODUCTION AND OVERVIEW OF MANUFACTURING 1
1.1 What Is Manufacturing? 2
1.2 Materials in Manufacturing 9
1.3 Manufacturing Processes 11
1.4 Production Systems 18
1.5 Manufacturing Economics 22
1.6 Recent Developments in Manufacturing 27
Part I Material Properties and Product Attributes 36
2 THE NATURE OF MATERIALS 36
2.1 Atomic Structure and the Elements 37
2.2 Bonding between Atoms and Molecules 39
2.3 Crystalline Structures 41
2.4 Noncrystalline (Amorphous) Structures 47
2.5 Engineering Materials 49
3 MECHANICAL PROPERTIES OF MATERIALS 52
3.1 Stress?Strain Relationships 52
3.2 Hardness 67
3.3 Effect of Temperature on Properties 71
3.4 Fluid Properties 73
3.5 Viscoelastic Behavior of Polymers 76
4 PHYSICAL PROPERTIES OF MATERIALS 83
4.1 Volumetric and Melting Properties 83
4.2 Thermal Properties 86
4.3 Mass Diffusion 88
4.4 Electrical Properties 90
4.5 Electrochemical Processes 92
5 DIMENSIONS, SURFACES, AND THEIR MEASUREMENT 95
5.1 Dimensions, Tolerances, and Related Attributes 96
5.2 Measuring Instruments and Gages 97
5.3 Surfaces 106
5.4 Measurement of Surfaces 112
5.5 Effect of Manufacturing Processes 114
Part II Engineering Materials 118
6 METALS 118
6.1 Alloys and Phase Diagrams 119
6.2 Ferrous Metals 124
6.3 Nonferrous Metals 142
6.4 Superalloys 155
7 CERAMICS 159
7.1 Structure and Properties of Ceramics 160
7.2 Traditional Ceramics 163
7.3 New Ceramics 165
7.4 Glass 168
7.5 Some Important Elements Related to Ceramics 172
8 POLYMERS 176
8.1 Fundamentals of Polymer Science and Technology 178
8.2 Thermoplastic Polymers 189
8.3 Thermosetting Polymers 196
8.4 Elastomers 200
8.5 Polymer Recycling and Biodegradability 208
9 COMPOSITE MATERIALS 212
9.1 Technology and Classification of Composite Materials 213
9.2 Metal Matrix Composites 222
9.3 Ceramic Matrix Composites 224
9.4 Polymer Matrix Composites 225
Part III Solidifi cation Processes 230
10 FUNDAMENTALS OF METAL CASTING 230
10.1 Overview of Casting Technology 233
10.2 Heating and Pouring 235
10.3 Solidifi cation and Cooling 239
11 METAL CASTING PROCESSES 251
11.1 Sand Casting 251
11.2 Other Expendable-Mold Casting Processes 257
11.3 Permanent-Mold Casting Processes 263
11.4 Foundry Practice 273
11.5 Casting Quality 277
11.6 Metals for Casting 279
11.7 Product Design Considerations 281
12 GLASSWORKING 287
12.1 Raw Materials Preparation and Melting 287
12.2 Shaping Processes in Glassworking 288
12.3 Heat Treatment and Finishing 294
12.4 Product Design Considerations 295
13 SHAPING PROCESSES FOR PLASTICS 297
13.1 Properties of Polymer Melts 299
13.2 Extrusion 301
13.3 Production of Sheet and Film 311
13.4 Fiber and Filament Production (Spinning) 314
13.5 Coating Processes 315
13.6 Injection Molding 316
13.7 Compression and Transfer Molding 327
13.8 Blow Molding and Rotational Molding 328
13.9 Thermoforming 334
13.10 Casting 338
13.11 Polymer Foam Processing and Forming 339
13.12 Product Design Considerations 341
14 PROCESSING OF POLYMER MATRIX COMPOSITES AND RUBBER 348
14.1 Overview of PMC Processing 349
14.2 Open Mold Processes 352
14.3 Closed Mold Processes 356
14.4 Other PMC Shaping Processes 359
14.5 Rubber Processing and Shaping 364
14.6 Manufacture of Tires and Other Rubber Products 369
Part IV Particulate Processing of Metals and Ceramics 375
15 POWDER METALLURGY 375
15.1 Characterization of Engineering Powders 377
15.2 Production of Metallic Powders 381
15.3 Conventional Pressing and Sintering 383
15.4 Alternative Pressing and Sintering Techniques 390
15.5 Materials and Products for Powder Metallurgy 393
15.6 Design Considerations in Powder Metallurgy 394
16 PROCESSING OF CERAMICS AND CERMETS 400
16.1 Processing of Traditional Ceramics 401
16.2 Processing of New Ceramics 408
16.3 Processing of Cermets 411
16.4 Product Design Considerations 413
Part V Metal Forming and Sheet Metalworking 416
17 FUNDAMENTALS OF METAL FORMING 416
17.1 Overview of Metal Forming 416
17.2 Material Behavior in Metal Forming 419
17.3 Temperature in Metal Forming 421
17.4 Strain Rate Sensitivity 423
17.5 Friction and Lubrication in Metal Forming 425
18 BULK DEFORMATION PROCESSES IN METAL WORKING 429
18.1 Rolling 430
18.2 Other Deformation Processes Related to Rolling 438
18.3 Forging 440
18.4 Other Deformation Processes Related to Forging 452
18.5 Extrusion 457
18.6 Wire and Bar Drawing 468
19 SHEET METALWORKING 481
19.1 Cutting Operations 482
19.2 Bending Operations 488
19.3 Drawing 493
19.4 Other Sheet-Metal-Forming Operations 500
19.5 Dies and Presses for Sheet-Metal Processes 503
19.6 Sheet-Metal Operations Not Performed on Presses 510
19.7 Bending of Tube Stock 516
Part VI Material Removal Processes 522
20 THEORY OF METAL MACHINING 522
20.1 Overview of Machining Technology 524
20.2 Theory of Chip Formation in Metal Machining 528
20.3 Force Relationships and the Merchant Equation 532
20.4 Power and Energy Relationships in Machining 538
20.5 Cutting Temperature 540
21 MACHINING OPERATIONS AND MACHINE TOOLS 548
21.1 Machining and Part Geometry 548
21.2 Turning and Related Operations 552
21.3 Drilling and Related Operations 561
21.4 Milling 566
21.5 Machining Centers and Turning Centers 574
21.6 Other Machining Operations 576
21.7 Machining Operations for Special Geometries 581
21.8 High-Speed Machining 589
22 CUTTING-TOOL TECHNOLOGY 596
22.1 Tool Life 596
22.2 Tool Materials 603
22.3 Tool Geometry 613
22.4 Cutting Fluids 623
23 ECONOMIC AND PRODUCT DESIGN CONSIDERATIONS IN MACHINING 632
23.1 Machinability 632
23.2 Tolerances and Surface Finish 635
23.3 Selection of Cutting Conditions 639
23.4 Product Design Considerations in Machining 646
24 GRINDING AND OTHER ABRASIVE PROCESSES 653
24.1 Grinding 653
24.2 Related Abrasive Processes 671
25 NONTRADITIONAL MACHINING AND THERMAL CUTTING PROCESSES 678
25.1 Mechanical Energy Processes 679
25.2 Electrochemical Machining Processes 683
25.3 Thermal Energy Processes 687
25.4 Chemical Machining 696
25.5 Application Considerations 702
Part VII Property Enhancing and Surface Processing Operations 709
26 HEAT TREATMENT OF METALS 709
26.1 Annealing 710
26.2 Martensite Formation in Steel 710
26.3 Precipitation Hardening 714
26.4 Surface Hardening 716
26.5 Heat Treatment Methods and Facilities 717
27 SURFACE PROCESSING OPERATIONS 721
27.1 Industrial Cleaning Processes 722
27.2 Diffusion and Ion Implantation 726
27.3 Plating and Related Processes 728
27.4 Conversion Coating 732
27.5 Vapor Deposition Processes 734
27.6 Organic Coatings 740
27.7 Porcelain Enameling and Other Ceramic Coatings 743
27.8 Thermal and Mechanical Coating Processes 744
Part VIII Joining and Assembly Processes 748
28 FUNDAMENTALS OF WELDING 748
28.1 Overview of Welding Technology 750
28.2 The Weld Joint 753
28.3 Physics of Welding 755
28.4 Features of a Fusion-Welded Joint 760
29 WELDING PROCESSES 765
29.1 Arc Welding 765
29.2 Resistance Welding 776
29.3 Oxyfuel Gas Welding 783
29.4 Other Fusion-Welding Processes 787
29.5 Solid-State Welding 790
29.6 Weld Quality 796
29.7 Weldability 800
29.8 Design Considerations in Welding 801
30 BRAZING, SOLDERING, AND ADHESIVE BONDING 807
30.1 Brazing 807
30.2 Soldering 814
30.3 Adhesive Bonding 818
31 MECHANICAL ASSEMBLY 825
31.1 Threaded Fasteners 826
31.2 Rivets and Eyelets 833
31.3 Assembly Methods Based on Interference Fits 834
31.4 Other Mechanical Fastening Methods 838
31.5 Molding Inserts and Integral Fasteners 839
31.6 Design for Assembly 841
Part IX Special Processing and Assembly Technologies 847
32 RAPID PROTOTYPING AND ADDITIVE MANUFACTURING 847
32.1 Fundamentals of Rapid Prototyping and Additive Manufacturing 849
32.2 Additive Manufacturing Processes 852
32.3 Cycle Time and Cost Analysis 860
32.4 Additive Manufacturing Applications 864
33 PROCESSING OF INTEGRATED CIRCUITS 869
33.1 Overview of IC Processing 871
33.2 Silicon Processing 874
33.3 Lithography 879
33.4 Layer Processes Used in IC Fabrication 883
33.5 Integrating the Fabrication Steps 890
33.6 IC Packaging 892
33.7 Yields in IC Processing 898
34 ELECTRONICS ASSEMBLY AND PACKAGING 904
34.1 Electronics Packaging 904
34.2 Printed Circuit Boards 906
34.3 Printed Circuit Board Assembly 915
34.4 Electrical Connector Technology 923
35 MICROFABRICATION TECHNOLOGIES 928
35.1 Microsystem Products 928
35.2 Microfabrication Processes 935
36 NANOFABRICATION TECHNOLOGIES 945
36.1 Nanotechnology Products and Applications 946
36.2 Introduction to Nanoscience 951
36.3 Nanofabrication Processes 955
Part X Manufacturing Systems 964
37 AUTOMATION TECHNOLOGIES FOR MANUFACTURING SYSTEMS 964
37.1 Automation Fundamentals 965
37.2 Hardware for Automation 968
37.3 Computer Numerical Control 973
37.4 Industrial Robotics 986
38 INTEGRATED MANUFACTURING SYSTEMS 997
38.1 Material Handling 997
38.2 Fundamentals of Production Lines 1000
38.3 Manual Assembly Lines 1002
38.4 Automated Production Lines 1006
38.5 Cellular Manufacturing 1011
38.6 Flexible Manufacturing Systems and Cells 1016
38.7 Computer Integrated Manufacturing 1022
Part XI Manufacturing Support Systems 1028
39 PROCESS PLANNING AND PRODUCTION CONTROL 1028
39.1 Process Planning 1030
39.2 Other Manufacturing Engineering Functions 1038
39.3 Production Planning and Control 1042
39.4 Just-In-Time Delivery Systems 1049
39.5 Lean Production 1052
40 QUALITY CONTROL AND INSPECTION 1058
40.1 Product Quality 1058
40.2 Process Capability and Tolerances 1059
40.3 Statistical Process Control 1061
40.4 Quality Programs in Manufacturing 1066
40.5 Inspection Principles 1072
40.6 Modern Inspection Technologies 1075
1.1 What Is Manufacturing? 2
1.2 Materials in Manufacturing 9
1.3 Manufacturing Processes 11
1.4 Production Systems 18
1.5 Manufacturing Economics 22
1.6 Recent Developments in Manufacturing 27
Part I Material Properties and Product Attributes 36
2 THE NATURE OF MATERIALS 36
2.1 Atomic Structure and the Elements 37
2.2 Bonding between Atoms and Molecules 39
2.3 Crystalline Structures 41
2.4 Noncrystalline (Amorphous) Structures 47
2.5 Engineering Materials 49
3 MECHANICAL PROPERTIES OF MATERIALS 52
3.1 Stress?Strain Relationships 52
3.2 Hardness 67
3.3 Effect of Temperature on Properties 71
3.4 Fluid Properties 73
3.5 Viscoelastic Behavior of Polymers 76
4 PHYSICAL PROPERTIES OF MATERIALS 83
4.1 Volumetric and Melting Properties 83
4.2 Thermal Properties 86
4.3 Mass Diffusion 88
4.4 Electrical Properties 90
4.5 Electrochemical Processes 92
5 DIMENSIONS, SURFACES, AND THEIR MEASUREMENT 95
5.1 Dimensions, Tolerances, and Related Attributes 96
5.2 Measuring Instruments and Gages 97
5.3 Surfaces 106
5.4 Measurement of Surfaces 112
5.5 Effect of Manufacturing Processes 114
Part II Engineering Materials 118
6 METALS 118
6.1 Alloys and Phase Diagrams 119
6.2 Ferrous Metals 124
6.3 Nonferrous Metals 142
6.4 Superalloys 155
7 CERAMICS 159
7.1 Structure and Properties of Ceramics 160
7.2 Traditional Ceramics 163
7.3 New Ceramics 165
7.4 Glass 168
7.5 Some Important Elements Related to Ceramics 172
8 POLYMERS 176
8.1 Fundamentals of Polymer Science and Technology 178
8.2 Thermoplastic Polymers 189
8.3 Thermosetting Polymers 196
8.4 Elastomers 200
8.5 Polymer Recycling and Biodegradability 208
9 COMPOSITE MATERIALS 212
9.1 Technology and Classification of Composite Materials 213
9.2 Metal Matrix Composites 222
9.3 Ceramic Matrix Composites 224
9.4 Polymer Matrix Composites 225
Part III Solidifi cation Processes 230
10 FUNDAMENTALS OF METAL CASTING 230
10.1 Overview of Casting Technology 233
10.2 Heating and Pouring 235
10.3 Solidifi cation and Cooling 239
11 METAL CASTING PROCESSES 251
11.1 Sand Casting 251
11.2 Other Expendable-Mold Casting Processes 257
11.3 Permanent-Mold Casting Processes 263
11.4 Foundry Practice 273
11.5 Casting Quality 277
11.6 Metals for Casting 279
11.7 Product Design Considerations 281
12 GLASSWORKING 287
12.1 Raw Materials Preparation and Melting 287
12.2 Shaping Processes in Glassworking 288
12.3 Heat Treatment and Finishing 294
12.4 Product Design Considerations 295
13 SHAPING PROCESSES FOR PLASTICS 297
13.1 Properties of Polymer Melts 299
13.2 Extrusion 301
13.3 Production of Sheet and Film 311
13.4 Fiber and Filament Production (Spinning) 314
13.5 Coating Processes 315
13.6 Injection Molding 316
13.7 Compression and Transfer Molding 327
13.8 Blow Molding and Rotational Molding 328
13.9 Thermoforming 334
13.10 Casting 338
13.11 Polymer Foam Processing and Forming 339
13.12 Product Design Considerations 341
14 PROCESSING OF POLYMER MATRIX COMPOSITES AND RUBBER 348
14.1 Overview of PMC Processing 349
14.2 Open Mold Processes 352
14.3 Closed Mold Processes 356
14.4 Other PMC Shaping Processes 359
14.5 Rubber Processing and Shaping 364
14.6 Manufacture of Tires and Other Rubber Products 369
Part IV Particulate Processing of Metals and Ceramics 375
15 POWDER METALLURGY 375
15.1 Characterization of Engineering Powders 377
15.2 Production of Metallic Powders 381
15.3 Conventional Pressing and Sintering 383
15.4 Alternative Pressing and Sintering Techniques 390
15.5 Materials and Products for Powder Metallurgy 393
15.6 Design Considerations in Powder Metallurgy 394
16 PROCESSING OF CERAMICS AND CERMETS 400
16.1 Processing of Traditional Ceramics 401
16.2 Processing of New Ceramics 408
16.3 Processing of Cermets 411
16.4 Product Design Considerations 413
Part V Metal Forming and Sheet Metalworking 416
17 FUNDAMENTALS OF METAL FORMING 416
17.1 Overview of Metal Forming 416
17.2 Material Behavior in Metal Forming 419
17.3 Temperature in Metal Forming 421
17.4 Strain Rate Sensitivity 423
17.5 Friction and Lubrication in Metal Forming 425
18 BULK DEFORMATION PROCESSES IN METAL WORKING 429
18.1 Rolling 430
18.2 Other Deformation Processes Related to Rolling 438
18.3 Forging 440
18.4 Other Deformation Processes Related to Forging 452
18.5 Extrusion 457
18.6 Wire and Bar Drawing 468
19 SHEET METALWORKING 481
19.1 Cutting Operations 482
19.2 Bending Operations 488
19.3 Drawing 493
19.4 Other Sheet-Metal-Forming Operations 500
19.5 Dies and Presses for Sheet-Metal Processes 503
19.6 Sheet-Metal Operations Not Performed on Presses 510
19.7 Bending of Tube Stock 516
Part VI Material Removal Processes 522
20 THEORY OF METAL MACHINING 522
20.1 Overview of Machining Technology 524
20.2 Theory of Chip Formation in Metal Machining 528
20.3 Force Relationships and the Merchant Equation 532
20.4 Power and Energy Relationships in Machining 538
20.5 Cutting Temperature 540
21 MACHINING OPERATIONS AND MACHINE TOOLS 548
21.1 Machining and Part Geometry 548
21.2 Turning and Related Operations 552
21.3 Drilling and Related Operations 561
21.4 Milling 566
21.5 Machining Centers and Turning Centers 574
21.6 Other Machining Operations 576
21.7 Machining Operations for Special Geometries 581
21.8 High-Speed Machining 589
22 CUTTING-TOOL TECHNOLOGY 596
22.1 Tool Life 596
22.2 Tool Materials 603
22.3 Tool Geometry 613
22.4 Cutting Fluids 623
23 ECONOMIC AND PRODUCT DESIGN CONSIDERATIONS IN MACHINING 632
23.1 Machinability 632
23.2 Tolerances and Surface Finish 635
23.3 Selection of Cutting Conditions 639
23.4 Product Design Considerations in Machining 646
24 GRINDING AND OTHER ABRASIVE PROCESSES 653
24.1 Grinding 653
24.2 Related Abrasive Processes 671
25 NONTRADITIONAL MACHINING AND THERMAL CUTTING PROCESSES 678
25.1 Mechanical Energy Processes 679
25.2 Electrochemical Machining Processes 683
25.3 Thermal Energy Processes 687
25.4 Chemical Machining 696
25.5 Application Considerations 702
Part VII Property Enhancing and Surface Processing Operations 709
26 HEAT TREATMENT OF METALS 709
26.1 Annealing 710
26.2 Martensite Formation in Steel 710
26.3 Precipitation Hardening 714
26.4 Surface Hardening 716
26.5 Heat Treatment Methods and Facilities 717
27 SURFACE PROCESSING OPERATIONS 721
27.1 Industrial Cleaning Processes 722
27.2 Diffusion and Ion Implantation 726
27.3 Plating and Related Processes 728
27.4 Conversion Coating 732
27.5 Vapor Deposition Processes 734
27.6 Organic Coatings 740
27.7 Porcelain Enameling and Other Ceramic Coatings 743
27.8 Thermal and Mechanical Coating Processes 744
Part VIII Joining and Assembly Processes 748
28 FUNDAMENTALS OF WELDING 748
28.1 Overview of Welding Technology 750
28.2 The Weld Joint 753
28.3 Physics of Welding 755
28.4 Features of a Fusion-Welded Joint 760
29 WELDING PROCESSES 765
29.1 Arc Welding 765
29.2 Resistance Welding 776
29.3 Oxyfuel Gas Welding 783
29.4 Other Fusion-Welding Processes 787
29.5 Solid-State Welding 790
29.6 Weld Quality 796
29.7 Weldability 800
29.8 Design Considerations in Welding 801
30 BRAZING, SOLDERING, AND ADHESIVE BONDING 807
30.1 Brazing 807
30.2 Soldering 814
30.3 Adhesive Bonding 818
31 MECHANICAL ASSEMBLY 825
31.1 Threaded Fasteners 826
31.2 Rivets and Eyelets 833
31.3 Assembly Methods Based on Interference Fits 834
31.4 Other Mechanical Fastening Methods 838
31.5 Molding Inserts and Integral Fasteners 839
31.6 Design for Assembly 841
Part IX Special Processing and Assembly Technologies 847
32 RAPID PROTOTYPING AND ADDITIVE MANUFACTURING 847
32.1 Fundamentals of Rapid Prototyping and Additive Manufacturing 849
32.2 Additive Manufacturing Processes 852
32.3 Cycle Time and Cost Analysis 860
32.4 Additive Manufacturing Applications 864
33 PROCESSING OF INTEGRATED CIRCUITS 869
33.1 Overview of IC Processing 871
33.2 Silicon Processing 874
33.3 Lithography 879
33.4 Layer Processes Used in IC Fabrication 883
33.5 Integrating the Fabrication Steps 890
33.6 IC Packaging 892
33.7 Yields in IC Processing 898
34 ELECTRONICS ASSEMBLY AND PACKAGING 904
34.1 Electronics Packaging 904
34.2 Printed Circuit Boards 906
34.3 Printed Circuit Board Assembly 915
34.4 Electrical Connector Technology 923
35 MICROFABRICATION TECHNOLOGIES 928
35.1 Microsystem Products 928
35.2 Microfabrication Processes 935
36 NANOFABRICATION TECHNOLOGIES 945
36.1 Nanotechnology Products and Applications 946
36.2 Introduction to Nanoscience 951
36.3 Nanofabrication Processes 955
Part X Manufacturing Systems 964
37 AUTOMATION TECHNOLOGIES FOR MANUFACTURING SYSTEMS 964
37.1 Automation Fundamentals 965
37.2 Hardware for Automation 968
37.3 Computer Numerical Control 973
37.4 Industrial Robotics 986
38 INTEGRATED MANUFACTURING SYSTEMS 997
38.1 Material Handling 997
38.2 Fundamentals of Production Lines 1000
38.3 Manual Assembly Lines 1002
38.4 Automated Production Lines 1006
38.5 Cellular Manufacturing 1011
38.6 Flexible Manufacturing Systems and Cells 1016
38.7 Computer Integrated Manufacturing 1022
Part XI Manufacturing Support Systems 1028
39 PROCESS PLANNING AND PRODUCTION CONTROL 1028
39.1 Process Planning 1030
39.2 Other Manufacturing Engineering Functions 1038
39.3 Production Planning and Control 1042
39.4 Just-In-Time Delivery Systems 1049
39.5 Lean Production 1052
40 QUALITY CONTROL AND INSPECTION 1058
40.1 Product Quality 1058
40.2 Process Capability and Tolerances 1059
40.3 Statistical Process Control 1061
40.4 Quality Programs in Manufacturing 1066
40.5 Inspection Principles 1072
40.6 Modern Inspection Technologies 1075