Manufacturing, Engineering and Technology

CONTENTS
......Page 7
I.1 What is Manufacturing?
......Page 23
I.2 Product Design and Concurrent Engineering......Page 30
I.3 Design for Manufacture, Assembly, Disassembly, and Service......Page 33
I.4 Green Design and Manufacturing......Page 35
I.5 Selection of Materials......Page 37
I.6
Selection of Manufacturing Processes......Page 40
I.7
Computer-integrated Manufacturing......Page 48
I.8
Quality Assurance and Total Quality Management......Page 51
I.10
Manufacturing Costs and Global Competition......Page 54
I.11
General Trends in Manufacturing......Page 56
PART I: Fundamentals of Materials: Their Behavior and Manufacturing Properties......Page 58
1.1 Introduction
......Page 61
1.2 Types of Atomic Bonds
......Page 62
1.3 The Crystal Structure of Metals
......Page 63
1.4 Deformation and Strength of Single Crystals
......Page 65
1.5 Grains and Grain Boundaries
......Page 68
1.6 Plastic Deformation of Polycrystalline Metals
......Page 71
1.7 Recovery, Recrystallization, and Grain Growth
......Page 72
1.8 Cold, Warm, and Hot Working
......Page 73
Summary
......Page 74
2.1 Introduction
......Page 77
2.2 Tension
......Page 78
2.3 Compression
......Page 87
2.4 Tension
......Page 88
2.6 Hardness
......Page 89
2.7 Fatigue
......Page 95
2.9 Impact
......Page 96
2.10 Failure and Fracture of Materials in Manufacturing and in Service
......Page 97
2.11 Residual Stresses
......Page 102
2.12 Work, Heat, and Temperature
......Page 103
Summary
......Page 104
3.1 Introduction
......Page 109
3.2 Density
......Page 110
3.4 Specific Heat
......Page 113
3.6 Thermal Expansion
......Page 114
3.7 Electrical, Magnetic, and Optical Properties
......Page 115
3.8 Corrosion Resistance
......Page 116
Summary
......Page 118
4.1 Introduction
......Page 121
4.2 Structure of Alloys
......Page 122
4.3 Phase Diagrams
......Page 124
4.4 The Iron-Carbon System
......Page 128
4.5 The Iron-Iron-carbide Phase Diagram and the Development of Microstructures in Steels
......Page 129
4.6 Cast Irons
......Page 131
4.8 Hardenability of Ferrous Alloys
......Page 136
4.9 Heat Treatment of Nonferrous Alloys and Stainless Steels
......Page 138
4.10 Case Hardening
......Page 140
4.11 Annealing
......Page 142
4.12 Heat-treating Furnaces and Equipment
......Page 144
4.13 Design Considerations for Heat Treating
......Page 146
Summary
......Page 147
5.1 Introduction
......Page 150
5.2 Production of Iron and Steel
......Page 151
5.3 Casting of Ingots
......Page 154
5.4 Continuous Casting
......Page 155
5.5 Carbon and Alloy Steels
......Page 157
5.6 Stainless Steels
......Page 164
5.7 Tool and Die Steels
......Page 166
Summary
......Page 168
6.1 Introduction
......Page 172
6.2 Aluminum and Aluminum Alloys
......Page 173
6.3 Magnesium and Magnesium Alloys
......Page 178
6.4 Copper and Copper Alloys
......Page 179
6.5 Nickel and Nickel Alloys
......Page 181
6.6 Superalloys
......Page 182
6.7 Titanium and Titanium Alloys
......Page 183
6.8 Refractory Metals and Alloys
......Page 184
6.11 Low-melting Alloys
......Page 185
6.13 Shape-memory Alloys (Smart Materials)
......Page 187
6.15 Metal Foams
......Page 188
Summary
......Page 189
7.1 Introduction
......Page 192
7.2 The Structure of Polymers
......Page 194
7.3 Thermoplastics
......Page 201
7.5 Additives in Plastics
......Page 205
7.6 General Properties and Applications of Thermoplastics
......Page 206
7.7 General Properties and Applications of Thermosetting Plastics
......Page 209
7.8 Biodegradable Plastics
......Page 211
7.9 Elastomers (Rubbers)
......Page 212
Summary
......Page 213
8.1 Introduction
......Page 217
8.2 The Structure of Ceramics
......Page 218
8.3 General Properties and Applications of Ceramics
......Page 222
8.4 Glasses
......Page 226
8.5 Glass Ceramics
......Page 228
8.6 Graphite
......Page 229
8.8 Nanomaterials
......Page 231
Summary
......Page 233
9.1 Introduction
......Page 237
9.2 The Structure of Reinforced Plastics
......Page 238
9.3 Properties of Reinforced Plastics
......Page 243
9.4 Applications of Reinforced Plastics
......Page 246
9.5 Metal-matrix Composites
......Page 248
9.6 Ceramic-matrix Composites
......Page 250
9.7 Other Composites
......Page 251
Summary
......Page 252
PART II: Metal-Casting Processes and Equipment
......Page 256
10.1 Introduction
......Page 258
10.2 Solidification of Metals
......Page 259
10.3 Fluid Flow
......Page 264
10.4 Fluidity of Molten Metal
......Page 266
10.5 Heat Transfer
......Page 268
10.6 Defects
......Page 270
Summary
......Page 274
11.1 Introduction
......Page 279
11.2 Expendable-mold, Permanent-pattern Casting Processes
......Page 283
11.3 Expendable-mold, Expendable-pattern Casting Processes
......Page 291
11.4 Permanent-mold Casting Processes
......Page 298
11.5 Casting Techniques for Single-crystal Components
......Page 306
11.6 Rapid Solidification
......Page 307
11.8 Melting Practice and Furnaces
......Page 308
Summary
......Page 310
12.2 Design Considerations in Casting
......Page 315
12.3 Casting Alloys
......Page 323
12.4 Economics of Casting
......Page 328
Summary
......Page 329
PART III: Forming and Shaping Processes and Equipment
......Page 333
13.1 Introduction
......Page 336
13.2 The Flat-rolling Process
......Page 338
13.3 Flat-rolling Practice
......Page 342
13.4 Rolling Mills
......Page 345
13.5 Various Rolling Processes and Mills
......Page 347
Summary
......Page 352
14.1 Introduction
......Page 355
14.2 Open-die Forging
......Page 357
14.3 Impression-die and Closed-die Forging
......Page 359
14.4 Various Forging Operations
......Page 363
14.5 Forgeability of Metals; Forging Defects
......Page 368
14.6 Die Design, Die Materials, and Lubrication
......Page 369
14.7 Die-manufacturing Methods and Die Failures
......Page 371
14.8 Forging Machines
......Page 373
14.9 Economics of Forging
......Page 375
Summary
......Page 377
15.1 Introduction
......Page 380
15.2 The Extrusion Process
......Page 382
15.3 Hot Extrusion
......Page 384
15.4 Cold Extrusion
......Page 388
15.5 Extrusion Defects
......Page 391
15.7 The Drawing Process
......Page 393
15.8 Drawing Practice
......Page 395
15.10 Drawing Equipment
......Page 397
Summary
......Page 398
16.1 Introduction
......Page 401
16.2 Shearing
......Page 402
16.3 Sheet-metal Characteristics and Formability
......Page 412
16.4 Formability Tests for Sheet Metals
......Page 414
16.5 Bending Sheets, Plates, and Tubes
......Page 417
16.6 Miscellaneous Bending and Related Operations
......Page 421
16.7 Deep Drawing
......Page 427
16.8 Rubber Forming and Hydroforming
......Page 433
16.9 Spinning
......Page 437
16.10 Superplastic Forming
......Page 440
16.11 Specialized Forming Processes
......Page 441
16.12 Manufacturing of Metal Honeycomb Structures
......Page 446
16.13 Design Considerations in Sheet-metal Forming
......Page 448
16.14 Equipment for Sheet-metal Forming
......Page 450
16.15 Economics of Sheet-forming Operations
......Page 451
Summary
......Page 452
17.1 Introduction
......Page 457
17.2 Production of Metal Powders
......Page 458
17.3 Compaction of Metal Powders
......Page 464
17.4 Sintering
......Page 472
17.5 Secondary and Finishing Operations
......Page 476
17.6 Design Considerations
......Page 477
17.7 Process Capabilities
......Page 479
17.8 Economics of Powder Metallurgy
......Page 480
Summary
......Page 482
18.1 Introduction
......Page 485
18.2 Shaping Ceramics
......Page 486
18.3 Forming and Shaping of Glass
......Page 492
18.4 Techniques for Strengthening and Annealing Glass
......Page 496
18.5 Design Considerations for Ceramics and Glasses
......Page 498
18.6 Processing of Superconductors
......Page 499
Summary
......Page 500
19.1 Introduction
......Page 504
19.2 Extrusion
......Page 506
19.3 Injection Molding
......Page 513
19.4 Blow Molding
......Page 519
19.5 Rotational Molding
......Page 521
19.6 Thermoforming
......Page 522
19.7 Compression Molding
......Page 523
19.8 Transfer Molding
......Page 524
19.9 Casting
......Page 525
19.10 Foam Molding
......Page 526
19.12 Processing Elastomers
......Page 527
19.13 Processing Polymer-matrix Composites
......Page 528
19.14 Processing Metal-matrix and Ceramic-matrix Composites
......Page 537
19.15 Design Considerations
......Page 538
19.16 Economics of Processing Plastics and Composite Materials
......Page 540
Summary
......Page 541
20.1 Introduction
......Page 545
20.2 Subtractive Processes
......Page 548
20.3 Additive Processes
......Page 550
20.4 Virtual Prototyping
......Page 561
20.5 Direct Manufacturing and Rapid Tooling
......Page 562
Summary
......Page 569
PART IV: Machining Processes and Machine Tools
......Page 572
21.1 Introduction
......Page 575
21.2 Mechanics of Cutting
......Page 577
21.3 Cutting Forces and Power
......Page 587
21.4 Temperatures in Cutting
......Page 590
21.5 Tool Life: Wear and Failure
......Page 593
21.6 Surface Finish and Integrity
......Page 600
21.7 Machinability
......Page 602
Summary
......Page 606
22.1 Introduction
......Page 610
22.2 High-speed Steels
......Page 614
22.4 Carbides
......Page 615
22.5 Coated Tools
......Page 619
22.6 Alumina-based Ceramics
......Page 623
22.9 Diamond
......Page 624
22.10 Whisker-reinforced Materials and Nanomaterials
......Page 625
22.12 Cutting Fluids
......Page 626
Summary
......Page 631
23.1 Introduction
......Page 634
23.2 The Turning Process
......Page 637
23.3 Lathes and Lathe Operations
......Page 645
23.4 Boring and Boring Machines
......Page 660
23.5 Drilling, Drills, and Drilling Machines
......Page 662
23.6 Reaming and Reamers
......Page 671
23.7 Tapping and Taps
......Page 672
Summary
......Page 674
24.1 Introduction
......Page 678
24.2 Milling and Milling Machines
......Page 679
24.3 Planing and Shaping
......Page 693
24.4 Broaching and Broaching Machines
......Page 694
24.5 Sawing
......Page 697
24.7 Gear Manufacturing by Machining
......Page 700
Summary
......Page 708
25.1 Introduction
......Page 712
25.2 Machining Centers
......Page 713
25.3 Machine-tool Structures
......Page 721
25.4 Vibration and Chatter in Machining Operations
......Page 725
25.5 High-speed Machining
......Page 728
25.7 Ultraprecision Machining
......Page 730
25.8 Machining Economics
......Page 732
Summary
......Page 736
26.1 Introduction
......Page 738
26.2 Abrasives and Bonded Abrasives 
......Page 740
26.3 The Grinding Process
......Page 746
26.4 Grinding Operations and Machines
......Page 755
26.6 Ultrasonic Machining
......Page 763
26.7 Finishing Operations
......Page 765
26.8 Deburring Operations
......Page 769
26.9 Economics of Abrasiv Maching and Finishing Operations
......Page 772
Summary
......Page 773
27.1 Introduction
......Page 778
27.2 Chemical Machining
......Page 780
27.3 Electrochemical Machining
......Page 784
27.4 Electrochemical Grinding
......Page 787
27.5 Electrical-discharge Machining
......Page 788
27.6
 Laser-beam Machining......Page 793
27.7 Electron-beam Machining
......Page 796
27.8 Water-jet Machining
......Page 797
27.9 Abrasive-jet Machining
......Page 798
27.10 Hybrid Machining Systems
......Page 799
27.11 Economics of Advanced Machining Processes
......Page 800
Summary
......Page 803
PART V: Micromanufacturing and Fabrication of Microelectronic Devices
......Page 806
28.1 Introduction
......Page 809
28.2 Clean Rooms
......Page 812
28.3 Semiconductors and Silicon
......Page 813
28.4 Crystal Growing and Wafer Preparation
......Page 814
28.5 Film Deposition
......Page 817
28.6 Oxidation
......Page 818
28.7 Lithography
......Page 819
28.8 Etching
......Page 827
28.9 Diffusion and Ion Implantation
......Page 835
28.10 Metallization and Testing
......Page 837
28.11 Wire Bonding and Packaging
......Page 839
28.12 Yield and Reliability
......Page 844
28.13 Printed Circuit Boards
......Page 845
Summary
......Page 846
29.1 Introduction
......Page 850
29.2 Micromaching of MEMS Devices
......Page 852
29.3 The LIGA Microfabrication Process
......Page 863
29.4 Solid Free-form Fabrication of Devices
......Page 869
29.5 Nanoscale Manufacturing
......Page 874
Summary
......Page 877
PART VI: Joining Processes and Equipment
......Page 880
30.1 Introduction
......Page 884
30.2 Oxyfuel-gas Welding
......Page 885
30.3 Arc-welding Processes: Nonconsumable Electrode
......Page 888
30.4 Arc-welding Processes: Consumable Electrode
......Page 892
30.5 Electrodes for Arc Welding
......Page 898
30.7 Laser-beam Welding
......Page 899
30.8 Cutting
......Page 901
30.9 The Weld Joint, Quality, and Testing
......Page 903
30.10 Joint Design and Process Selection
......Page 912
Summary
......Page 916
31.1 Introduction
......Page 919
31.2 Cold Welding and Roll Bonding
......Page 920
31.3 Ultrasonic Welding
......Page 921
31.4 Friction Welding
......Page 922
31.5 Resistance Welding
......Page 924
31.6 Explosion Welding
......Page 932
31.7 Diffusion Bonding
......Page 933
31.8 Economics of Welding Operations
......Page 935
Summary
......Page 937
32.1 Introduction
......Page 940
32.2 Brazing
......Page 941
32.3 Soldering
......Page 945
32.4 Adhesive Bonding
......Page 950
32.5 Mechanical Fastening
......Page 958
32.6 Joining Plastics, Ceramics, and Glasses
......Page 961
32.7 Economics of Joining Operations
......Page 964
Summary
......Page 965
PART VII: Surface Technology
......Page 968
33.1 Introduction
......Page 970
33.2
Surface Structure and Integrity......Page 971
33.3 Surface Texture and Roughness
......Page 972
33.4 Friction
......Page 976
33.5 Wear
......Page 980
33.6 Lubrication
......Page 983
33.7 Metalworking Fluids and Their Selection
......Page 985
Summary
......Page 989
34.1 Introduction
......Page 992
34.2 Mechanical Surface Treatments
......Page 993
34.4 Case Hardening and Hard Facing
......Page 995
34.5 Thermal Spraying
......Page 996
34.6 Vapor Deposition
......Page 998
34.8 Laser Treatments
......Page 1001
34.9 Electroplating, Electroless Plating, and Electroforming
......Page 1002
34.10 Conversion Coatings
......Page 1005
34.11 Hot Dipping
......Page 1006
34.12 Porcelain Enameling; Ceramic and Organic Coatings
......Page 1007
34.13 Diamond Coating and Diamond-like Carbon
......Page 1008
34.15 Painting
......Page 1009
34.16 Cleaning of Surfaces
......Page 1010
Summary
......Page 1012
PART VIII: Engineering Metrology, Instrumentation, and Quality Assurance
......Page 1015
35.1 Introduction
......Page 1016
35.2 Measurement Standards
......Page 1017
35.3 Geometric Features of Parts; Analog and Digital Measurements
......Page 1018
35.4 Traditional Measuring Methods and Instruments
......Page 1019
35.5 Modern Measuring Instruments and Machines
......Page 1026
35.6 Automated Measurement and Inspection
......Page 1029
35.8 Geometric Dimensioning and Tolerancing
......Page 1030
Summary
......Page 1035
36.1 Introduction
......Page 1038
36.2 Product Quality
......Page 1039
36.3 Quality Assurance
......Page 1040
36.4 Total Quality Management
......Page 1041
36.5 Taguchi Methods
......Page 1043
36.6 The ISO and QS Standards
......Page 1047
36.7 Statistical Methods of Quality Control
......Page 1048
36.8 Statistical Process Control
......Page 1051
36.9 Reliability of Products and Processes
......Page 1057
36.10 Nondestructive Testing
......Page 1058
36.12 Automated Inspection
......Page 1062
Summary
......Page 1063
PART IX: Manufacturing in a Competitive Environment
......Page 1067
37.1 Introduction
......Page 1069
37.2 Automation
......Page 1071
37.3 Numerical Control
......Page 1078
37.4 Adaptive Control
......Page 1084
37.5 Material Handling and Movement
......Page 1086
37.6 Industrial Robots
......Page 1089
37.7 Sensor Technology
......Page 1095
37.8 Flexible Fixturing
......Page 1099
37.9 Assembly Systems
......Page 1101
37.10 Design Considerations for Fixturing, Assembly, Disassembly, and Servicing
......Page 1104
Summary
......Page 1107
38.1 Introduction
......Page 1111
38.3 Computer-integrated Manufacturing
......Page 1112
38.4 Computer-aided Design and Engineering
......Page 1115
38.6 Computer-aided Process Planning
......Page 1122
38.7 Computer Simulation of Manufacturing Processes and Systems
......Page 1125
38.8 Group Technology
......Page 1126
Summary
......Page 1133
39.1 Introduction
......Page 1135
39.2 Cellular Manufacturing
......Page 1136
39.3 Flexible Manufacturing Systems
......Page 1138
39.4 Holonic Manufacturing
......Page 1140
39.5 Just-in-time Production
......Page 1142
39.6 Lean Manufacturing
......Page 1143
39.7 Communications Networks in Manufacturing
......Page 1145
39.8 Artificial Intelligence
......Page 1147
Summary
......Page 1150
40.1 Introduction
......Page 1153
40.2 Product Design
......Page 1154
40.3 Product Quality and Life Expectancy
......Page 1157
40.4 Life-cycle Assessment and Sustainable Manufacturing
......Page 1158
40.5 Material Selection for Products
......Page 1160
40.6 Material Substitution
......Page 1164
40.7 Manufacturing Process Capabilities
......Page 1166
40.8 Process Selection
......Page 1170
40.9 Manufacturing Costs and Cost Reduction
......Page 1174
Summary
......Page 1179
INDEX
......Page 1182
List of Tables
......Page 1194
References to Various Topics
......Page 1196
List of Examples
......Page 1197