Waubonsee Community College

Manufacturing engineering and technology, Serope Kalpakjian, Illinois Institute of Technology, Steven R. Schmid, The University of Notre Dame

eng

Includes bibliographical references and index

illustrations

index present

non fiction

Manufacturing engineering and technology

bibliography

819640528

Serope Kalpakjian, Illinois Institute of Technology, Steven R. Schmid, The University of Notre Dame

The book provides numerous examples and case studies, as well as comprehensive and up-to-date coverage of all topics relevant to modern manufacturing, as a solid background for students as well as for professionals. -- Preface

Machine generated contents note: I.1.What is Manufacturing? -- I.2.Product Design and Concurrent Engineering -- I.3.Design for Manufacture, Assembly, Disassembly, and Service -- I.4.Green Design and Manufacturing -- I.5.Selection of Materials -- I.6.Selection of Manufacturing Processes -- I.7.Computer-integrated Manufacturing -- I.8.Quality Assurance and Total Quality Management -- I.9.Lean Production and Agile Manufacturing -- I.10.Manufacturing Costs and Global Competition -- I.11.Trends in Manufacturing -- pt. I Fundamentals of Materials: Behavior and Manufacturing Properties -- 1.The Structure of Metals -- 1.1.Introduction -- 1.2.Types of Atomic Bonds -- 1.3.The Crystal Structure of Metals -- 1.4.Deformation and Strength of Single Crystals -- 1.5.Grains and Grain Boundaries -- 1.6.Plastic Deformation of Polycrystalline Metals -- 1.7.Recovery, Recrystallization, and Grain Growth -- 1.8.Cold, Warm, and Hot Working -- Summary -- Key Terms -- Bibliography -- Review Questions -- Qualitative Problems -- Quantitative Problems -- Synthesis, Design, and Projects -- 2.Mechanical Behavior, Testing, and Manufacturing Properties of Materials -- 2.1.Introduction -- 2.2.Tension -- 2.3.Compression -- 2.4.Torsion -- 2.5.Bending (Flexure) -- 2.6.Hardness -- 2.7.Fatigue -- 2.8.Creep -- 2.9.Impact -- 2.10.Failure and Fracture of Materials -- 2.11.Residual Stresses -- 2.12.Work, Heat, and Temperature -- Summary -- Key Terms -- Bibliography -- Review Questions -- Qualitative Problems -- Quantitative Problems -- Synthesis, Design, and Projects -- 3.Physical Properties of Materials -- 3.1.Introduction -- 3.2.Density -- 3.3.Melting Point -- 3.4.Specific Heat -- 3.5.Thermal Conductivity -- 3.6.Thermal Expansion -- 3.7.Electrical, Magnetic, and Optical Properties -- 3.8.Corrosion Resistance -- Summary -- Key Terms -- Bibliography -- Review Questions -- Qualitative Problems -- Quantitative Problems -- Synthesis, Design, and Projects -- 4.Metal Alloys: Their Structure and Strengthening by Heat Treatment -- 4.1.Introduction -- 4.2.Structure of Alloys -- 4.3.Phase Diagrams -- 4.4.The Iron-carbon System -- 4.5.The Iron-iron-carbide Phase Diagram and the Development of Microstructures in Steels -- 4.6.Cast Irons -- 4.7.Heat Treatment of Ferrous Alloys -- 4.8.Hardenability of Ferrous Alloys -- 4.9.Heat Treatment of Nonferrous Alloys and Stainless Steels -- 4.10.Case Hardening -- 4.11.Annealing -- 4.12.Heat-treating Furnaces and Equipment -- 4.13.Design Considerations for Heat Treating -- Summary -- Key Terms -- Bibliography -- Review Questions -- Qualitative Problems -- Quantitative Problems -- Synthesis, Design, and Projects -- 5.Ferrous Metals and Alloys: Production, General Properties, and Applications -- 5.1.Introduction -- 5.2.Production of Iron and Steel -- 5.3.Casting of Ingots -- 5.4.Continuous Casting -- 5.5.Carbon and Alloy Steels -- 5.6.Stainless Steels -- 5.7.Tool and Die Steels -- Summary -- Key Terms -- Bibliography -- Review Questions -- Qualitative Problems -- Quantitative Problems -- Synthesis, Design, and Projects -- 6.Nonferrous Metals and Alloys: Production, General Properties, and Applications -- 6.1.Introduction -- 6.2.Aluminum and Aluminum Alloys -- 6.3.Magnesium and Magnesium Alloys -- 6.4.Copper and Copper Alloys -- 6.5.Nickel and Nickel Alloys -- 6.6.Superalloys -- 6.7.Titanium-and Titanium Alloys -- 6.8.Refractory Metals and Alloys -- 6.9.Beryllium -- 6.10.Zirconium -- 6.11.Low-melting Alloys -- 6.12.Precious Metals -- 6.13.Shape-memory Alloys (Smart Materials) -- 6.14.Amorphous Alloys (Metallic Glasses) -- 6.15.Metal Foams -- Summary -- Key Terms -- Bibliography -- Review Questions -- Qualitative Problems -- Quantitative Problems -- Synthesis, Design, and Projects -- 7.Polymers: Structure, General Properties, and Applications -- 7.1.Introduction -- 7.2.The Structure of Polymers -- 7.3.Thermoplastics -- 7.4.Thermosetting Plastics -- 7.5.Additives in Plastics -- 7.6.General Properties and Applications of Thermoplastics -- 7.7.General Properties and Applications of Thermosetting Plastics -- 7.8.Biodegradable Plastics -- 7.9.Elastomers (Rubbers) -- Summary -- Key Terms -- Bibliography -- Review Questions -- Qualitative Problems -- Quantitative Problems -- Synthesis, Design, and Projects -- 8.Ceramics, Glass, Graphite, Diamond, and Nanomaterials: Structure, General Properties, and Applications -- 8.1.Introduction -- 8.2.The Structure of Ceramics -- 8.3.General Properties and Applications of Ceramics -- 8.4.Glasses -- 8.5.Glass Ceramics -- 8.6.Graphite -- 8.7.Diamond -- 8.8.Nanomaterials -- Summary -- Key Terms -- Bibliography -- Review Questions -- Qualitative Problems -- Quantitative Problems -- Synthesis, Design, and Projects -- 9.Composite Materials: Structure, General Properties, and Applications -- 9.1.Introduction -- 9.2.The Structure of Reinforced Plastics -- 9.3.Properties of Reinforced Plastics -- 9.4.Applications of Reinforced Plastics -- 9.5.Metal-matrix Composites -- 9.6.Ceramic-matrix Composites -- 9.7.Other Composites -- Summary -- Key Terms -- Bibliography -- Review Questions -- Qualitative Problems -- Quantitative Problems -- Synthesis, Design, and Projects -- pt. II Metal-casting Processes and Equipment -- 10.Fundamentals of Metal Casting -- 10.1.Introduction -- 10.2.Solidification of Metals -- 10.3.Fluid Flow -- 10.4.Fluidity of Molten Metal -- 10.5.Heat Transfer -- 10.6.Defects -- Summary -- Key Terms -- Bibliography -- Review Questions -- Qualitative Problems -- Quantitative Problems -- Synthesis, Design, and Projects -- 11.Metal-casting Processes and Equipment -- 11.1.Introduction -- 11.2.Expendable-mold, Permanent-pattern Casting Processes -- 11.3.Expendable-mold, Expendable-pattern Casting Processes -- 11.4.Permanent-mold Casting Processes -- 11.5.Casting Techniques for Single-crystal Components -- 11.6.Rapid Solidification -- 11.7.Inspection of Castings -- 11.8.Melting Practice and Furnaces -- 11.9.Foundries and Foundry Automation -- Summary -- Key Terms -- Bibliography -- Review Questions -- Qualitative Problems -- Quantitative Problems -- Synthesis, Design, and Projects -- 12.Metal Casting: Design, Materials, and Economics -- 12.1.Introduction -- 12.2.Design Considerations in Casting -- 12.3.Casting Alloys -- 12.4.Economics of Casting -- Summary -- Key Terms -- Bibliography -- Review Questions -- Qualitative Problems -- Quantitative Problems -- Synthesis, Design, and Projects -- ptNote continued: 19.15.Design Considerations -- 19.16.Economics of Processing Plastics and Composite Materials -- Summary -- Key Terms -- Bibliography -- Review Questions -- Qualitative Problems -- Quantitative Problems -- Synthesis, Design, and Projects -- 20.Rapid-prototyping Processes and Operations -- 20.1.Introduction -- 20.2.Subtractive Processes -- 20.3.Additive Processes -- 20.4.Virtual Prototyping -- 20.5.Self-replicating Machines -- 20.6.Direct Manufacturing and Rapid Tooling -- Summary -- Key Terms -- Bibliography -- Review Questions -- Qualitative Problems -- Quantitative Problems -- Synthesis, Design, and Projects -- pt. IV Machining Processes and Machine Tools -- 21.Fundamentals of Machining -- 21.1.Introduction -- 21.2.Mechanics of Cutting -- 21.3.Cutting Forces and Power -- 21.4.Temperatures in Cutting -- 21.5.Tool Life: Wear and Failure -- 21.6.Surface Finish and Integrity -- 21.7.Machinability -- Summary -- Key Terms -- Bibliography -- Review Questions -- Qualitative Problems -- Quantitative Problems -- Synthesis, Design, and Projects -- 22.Cutting-tool Materials and Cutting Fluids -- 22.1.Introduction -- 22.2.High-speed Steels -- 22.3.Cast-cobalt Alloys -- 22.4.Carbides -- 22.5.Coated Tools -- 22.6.Alumina-based Ceramics -- 22.7.Cubic Boron Nitride -- 22.8.Silicon-nitride-based Ceramics -- 22.9.Diamond -- 22.10.Whisker-reinforced Materials and Nanomaterials -- 22.11.Tool Costs and Reconditioning of Tools -- 22.12.Cutting Fluids -- Summary -- Key Terms -- Bibliography -- Review Questions -- Qualitative Problems -- Quantitative Problems -- Synthesis, Design, and Projects -- 23.Machining Processes: Turning and Hole Making -- 23.1.Introduction -- 23.2.The Turning Process -- 23.3.Lathes and Lathe Operations -- 23.4.Boring and Boring Machines -- 23.5.Drilling, Drills, and Drilling Machines -- 23.6.Reaming and Reamers -- 23.7.Tapping and Taps -- Summary -- Key Terms -- Bibliography -- Review Questions -- Qualitative Problems -- Quantitative Problems -- Synthesis, Design, and Projects -- 24.Machining Processes: Milling, Broaching, Sawing, Filing, and Gear Manufacturing -- 24.1.Introduction -- 24.2.Milling and Milling Machines -- 24.3.Planing and Shaping -- 24.4.Broaching and Broaching Machines -- 24.5.Sawing -- 24.6.Filing -- 24.7.Gear Manufacturing by Machining -- Summary -- Key Terms -- Bibliography -- Review Questions -- Qualitative Problems -- Quantitative Problems -- Synthesis, Design, and Projects -- 25.Machining Centers, Machine-tool Structures, and Machining Economics -- 25.1.Introduction -- 25.2.Machining Centers -- 25.3.Machine-tool Structures -- 25.4.Vibration and Chatter in Machining Operations -- 25.5.High-speed Machining -- 25.6.Hard Machining -- 25.7.Ultraprecision Machining -- 25.8.Machining Economics -- Summary -- Key Terms -- Bibliography -- Review Questions -- Qualitative Problems -- Quantitative Problems -- Synthesis, Design, and Projects -- 26.Abrasive Machining and Finishing Operations -- 26.1.Introduction -- 26.2.Abrasives and Bonded Abrasives -- 26.3.The Grinding Process -- 26.4.Grinding Operations and Machines -- 26.5.Design Considerations for Grinding -- 26.6.Ultrasonic Machining -- 26.7.Finishing Operations -- 26.8.Deburring Operations -- 26.9.Economics of Abrasive Machining and Finishing Operations -- Summary -- Key Terms -- Bibliography -- Review Questions -- Qualitative Problems -- Quantitative Problems -- Synthesis, Design, and Projects -- 27.Advanced Machining Processes and Equipment -- 27.1.Introduction -- 27.2.Chemical Machining -- 27.3.Electrochemical Machining -- 27.4.Electrochemical Grinding -- 27.5.Electrical-discharge Machining -- 27.6.Laser-beam Machining -- 27.7.Electron-beam Machining -- 27.8.Water-jet Machining -- 27.9.Abrasive-jet Machining -- 27.10.Hybrid Machining Systems -- 27.11.Economics of Advanced Machining Processes -- Summary -- Key Terms -- Bibliography -- Review Questions -- Qualitative Problems -- Quantitative Problems -- Synthesis, Design, and Projects -- ptIII Forming and Shaping Processes and Equipment -- 13.Metal-rolling Processes and Equipment -- 13.1.Introduction -- 13.2.The Flat-rolling Process -- 13.3.Flat-rolling Practice -- 13.4.Rolling Mills -- 13.5.Various Rolling Processes and Mills -- Summary -- Key Terms -- Bibliography -- Review Questions -- Qualitative Problems -- Quantitative Problems -- Synthesis, Design, and Projects -- 14.Metal-forging Processes and Equipment -- 14.1.Introduction -- 14.2.Open-die Forging -- 14.3.Impression-die and Closed-die Forging -- 14.4.Various Forging Operations -- 14.5.Forgeability of Metals; Forging Defects -- 14.6.Die Design, Die Materials, and Lubrication -- 14.7.Die-manufacturing Methods and Die Failure -- 14.8.Forging Machines -- 14.9.Economics of Forging -- Summary -- Key Terms -- Bibliography -- Review Questions -- Qualitative Problems -- Quantitative Problems -- Synthesis, Design, and Projects -- 15.Metal Extrusion and Drawing Processes and Equipment -- 15.1.Introduction -- 15.2.The Extrusion Process -- 15.3.Hot Extrusion -- 15.4.Cold Extrusion -- 15.5.Extrusion Defects -- 15.6.Design Considerations -- 15.7.Extrusion Equipment -- 15.8.The Drawing Process -- 15.9.Drawing Practice -- 15.10.Drawing Defects and Residual Stresses -- 15.11.Drawing Equipment -- Summary -- Key Terms -- Bibliography -- Review Questions -- Qualitative Problems -- Quantitative Problems -- Synthesis, Design, and Projects -- 16.Sheet-metal Forming Processes and Equipment -- 16.1.Introduction -- 16.2.Shearing -- 16.3.Sheet-metal Characteristics and Formability -- 16.4.Formability Tests for Sheet Metals -- 16.5.Bending Sheets, Plates, and Tubes -- 16.6.Miscellaneous Bending and Related Forming Operations -- 16.7.Deep Drawing -- 16.8.Rubber Forming and Hydroforming -- 16.9.Spinning -- 16.10.Superplastic Forming -- 16.11.Hot Stamping -- 16.12.Specialized Forming Processes -- 16.13.Manufacturing of Metal Honeycomb Structures -- 16.14.Design Considerations in Sheet-metal Forming -- 16.15.Equipment for Sheet-metal Forming -- 16.16.Economics of Sheet-forming Operations -- Summary -- Key Terms -- Bibliography -- Review Questions -- Qualitative Problems -- Quantitative Problems -- Synthesis, Design, and Projects -- 17.Powder Metal Processes and Equipment -- 17.1.Introduction -- 17.2.Production of Metal Powders -- 17.3.Compaction of Metal Powders -- 17.4.Sintering -- 17.5.Secondary and Finishing Operations -- 17.6.Design Considerations -- 17.7.Economics of Powder Metallurgy -- Summary -- Key Terms -- Bibliography -- Review Questions -- Qualitative Problems -- Quantitative Problems -- Synthesis, Design, and Projects -- 18.Ceramics, Glasses, and Superconductors: Processing and Equipment -- 18.1.Introduction -- 18.2.Shaping Ceramics -- 18.3.Forming and Shaping of Glass -- 18.4.Techniques for Strengthening and Annealing Glass -- 18.5.Design Considerations for Ceramics and Glasses -- 18.6.Processing of Superconductors -- Summary -- Key Terms -- Bibliography -- Review Questions -- Qualitative Problems -- Quantitative Problems -- Synthesis, Design, and Projects -- 19.Plastics and Composite Materials: Forming and Shaping -- 19.1.Introduction -- 19.2.Extrusion -- 19.3.Injection Molding -- 19.4.Blow Molding -- 19.5.Rotational Molding -- 19.6.Thermoforming -- 19.7.Compression Molding -- 19.8.Transfer Molding -- 19.9.Casting -- 19.10.Foam Molding -- 19.11.Cold Forming and Solid-phase Forming -- 19.12.Processing Elastomers -- 19.13.Processing Polymer-matrix Composites -- 19.14.Processing Metal-matrix and Ceramic-matrix Composites --V Micromanufacturing and Fabrication of Microelectronic Devices -- 28.Fabrication of Microelectronic Devices -- 28.1.Introduction -- 28.2.Clean Rooms -- 28.3.Semiconductors and Silicon -- 28.4.Crystal-Growing and Water Preparation -- 28.5.Film Deposition -- 28.6.Oxidation -- 28.7.Lithography -- 28.8.Etching -- 28.9.Diffusion and Ion Implantation -- 28.10.Metallization and Testing -- 28.11.Wire Bonding and Packaging -- 28.12.Yield and Reliability -- 28.13.Printed Circuit Boards -- Summary -- Key Terms -- Bibliography -- Review Questions -- Qualitative Problems -- Quantitative Problems -- Synthesis, Design, and Projects -- 29.Fabrication of Microelectromechanical Devices and Systems; Nanoscale Manufacturing -- 29.1.Introduction -- 29.2.Micromachining of MEMS Devices -- 29.3.Electroforming-based Processes -- 29.4.Solid Free-form Fabrication of Devices -- 29.5.Nanoscale Manufacturing -- Summary -- Key Terms -- Bibliography -- Review Questions -- Qualitative Problems -- Quantitative Problems -- Synthesis, Design, and Projects -- pt. VI Joining Processes and Equipment -- 30.Fusion-welding Processes -- 30.1.Introduction -- 30.2.Oxyfuel-gas Welding -- 30.3.Arc-welding Processes: Nonconsumable Electrode -- 30.4.Arc-welding Processes: Consumable Electrode -- 30.5.Electrodes for Arc Welding -- 30.6.Electron-beam Welding -- 30.7.Laser-beam Welding -- 30.8.Cutting -- 30.9.The Weld Joint, Weld Quality, and Testing -- 30.10.Joint Design and Process Selection -- Summary -- Key Terms -- Bibliography -- Review Questions -- Qualitative Problems -- Quantitative Problems -- Synthesis, Design, and Projects -- 31.Solid-State Welding Processes -- 31.1.Introduction -- 31.2.Cold Welding and Roll Bonding -- 31.3.Ultrasonic Welding -- 31.4.Friction Welding -- 31.5.Resistance Welding -- 31.6.Explosion Welding -- 31.7.Diffusion Bonding -- 31.8.Economics of Welding Operations -- Summary -- Key Terms -- Bibliography -- Review Questions -- Qualitative Problems -- Quantitative Problems -- Synthesis, Design, and Projects -- 32.Brazing, Soldering, Adhesive-bonding, and Mechanical Fastening Processes -- 32.1.Introduction -- 32.2.Brazing -- 32.3.Soldering -- 32.4.Adhesive-bonding -- 32.5.Mechanical Fastening -- 32.6.Joining Plastics, Ceramics, and Glasses -- 32.7.Economics of Joining Operations -- Summary -- Key Terms -- Bibliography -- Review Questions -- Qualitative Problems -- Quantitative Problems -- Synthesis, Design, and Projects -- pt. VII Surface Technology -- 33.Surface Roughness and Measurement; Friction, Wear, and Lubrication -- 33.1.Introduction -- 33.2.Surface Structure and Integrity -- 33.3.Surface Texture and Roughness -- 33.4.Friction -- 33.5.Wear -- 33.6.Lubrication -- 33.7.Metalworking Fluids and Their Selection -- Summary -- Key Terms -- Bibliography -- Review Questions -- Qualitative Problems -- Quantitative Problems -- Synthesis, Design, and Projects -- 34.Surface Treatments, Coatings, and Cleaning -- 34.1.Introduction -- 34.2.Mechanical Surface Treatments -- 34.3.Mechanical Plating and Cladding -- 34.4.Case Hardening and Hard Facing -- 34.5.Thermal Spraying -- 34.6.Vapor Deposition -- 34.7.Ion Implantation and Diffusion Coating -- 34.8.Laser Treatments -- 34.9.Electroplating, Electroless Plating, and Electroforming -- 34.10.Conversion Coatings -- 34.11.Hot Dipping -- 34.12.Porcelain Enameling; Ceramic and Organic Coatings -- 34.13.Diamond Coating and Diamond-like Carbon -- 34.14.Surface Texturing -- 34.15.Painting -- 34.16.Cleaning of Surfaces -- Summary -- Key Terms -- Bibliography -- Review Questions -- Qualitative Problems -- Quantitative Problems -- Synthesis, Design, and Projects -- ptVIII Engineering Metrology, Instrumentation, and Quality Assurance -- 35.Engineering Metrology and Instrumentation -- 35.1.Introduction -- 35.2.Measurement Standards -- 35.3.Geometric Features of Parts: Analog and Digital Measurements -- 35.4.Traditional Measuring Methods and Instruments -- 35.5.Modern Measuring Instruments and Machines -- 35.6.Automated Measurement -- 35.7.General Characteristics and Selection of Measuring Instruments -- 35.8.Geometric Dimensioning and Tolerancing -- Summary -- Key Terms -- Bibliography -- Review Questions -- Qualitative Problems -- Quantitative Problems -- Synthesis, Design, and Projects -- 36.Quality Assurance, Testing, and Inspection -- 36.1.Introduction -- 36.2.Product Quality -- 36.3.Quality Assurance -- 36.4.Total Quality Management -- 36.5.Taguchi Methods -- 36.6.The ISO and QS Standards -- 36.7.Statistical Methods of Quality Control -- 36.8.Statistical Process Control -- 36.9.Reliability of Products and Processes -- 36.10.Nondestructive Testing -- 36.11.Destructive Testing -- 36.12.Automated Inspection -- Summary -- Key Terms -- Bibliography -- Review Questions -- Qualitative Problems -- Quantitative Problems -- Synthesis, Design, and Projects -- pt. IX Manufacturing in a Competitive Environment -- 37.Automation of Manufacturing Processes and Operations -- 37.1.Introduction -- 37.2.Automation -- 37.3.Numerical Control -- 37.4.Adaptive Control -- 37.5.Material Handling and Movement -- 37.6.Industrial Robots -- 37.7.Sensor Technology -- 37.8.Flexible Fixturing -- 37.9.Assembly Systems -- 37.10.Design Considerations for Fixturing, Assembly, Disassembly, and Servicing -- 37.11.Economic Considerations -- Summary -- Key Terms -- Bibliography -- Review Questions -- Qualitative Problems -- Quantitative Problems -- Synthesis, Design, and Projects -- 38.Computer-aided Manufacturing -- 38.1.Introduction -- 38.2.Manufacturing Systems -- 38.3.Computer-integrated Manufacturing -- 38.4.Computer-aided Design and Engineering -- 38.5.Computer-aided Manufacturing -- 38.6.Computer-aided Process Planning -- 38.7.Computer Simulation of Manufacturing Processes and Systems -- 38.8.Group Technology -- Summary -- Key Terms -- Bibliography -- Review Questions -- Qualitative Problems -- Synthesis, Design, and Projects -- 39.Computer-integrated Manufacturing Systems --Note continued: 39.1.Introduction -- 39.2.Cellular Manufacturing -- 39.3.Flexible Manufacturing Systems -- 39.4.Holonic Manufacturing -- 39.5.Just-in-time Production -- 39.6.Lean Manufacturing -- 39.7.Communications Networks in Manufacturing -- 39.8.Artificial Intelligence -- 39.9.Economic Considerations -- Summary -- Key Terms -- Bibliography -- Review Questions -- Qualitative Problems -- Synthesis, Design, and Projects -- 40.Product Design and Manufacturing in a Competitive Environment -- 40.1.Introduction -- 40.2.Product Design -- 40.3.Product Quality -- 40.4.Life-cycle Assessment and Sustainable Manufacturing -- 40.5.Energy Consumption in Manufacturing -- 40.6.Material Selection for Products -- 40.7.Material Substitution -- 40.8.Manufacturing Process Capabilities -- 40.9.Process Selection -- 40.10.Manufacturing Costs and Cost Reduction -- Summary -- Key Terms -- Bibliography -- Review Questions -- Qualitative Problems -- Synthesis, Design, and Projects