Manufacturing Engineering and Technology

Cover
Contents
Preface
About the Authors
General Introduction
	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 General Trends in Manufacturing
Part I: Fundamentals of Materials: Their 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 in Manufacturing and in Service
		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, 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
Part 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
Part III: 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 Failures
		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 Extrusion Equipment
		15.7 The Drawing Process
		15.8 Drawing Practice
		15.9 Drawing Defects and Residual Stresses
		15.10 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 Operations
		16.7 Deep Drawing
		16.8 Rubber Forming and Hydroforming
		16.9 Spinning
		16.10 Superplastic Forming
		16.11 Specialized Forming Processes
		16.12 Manufacturing of Metal Honeycomb Structures
		16.13 Design Considerations in Sheet-metal Forming
		16.14 Equipment for Sheet-metal Forming
		16.15 Economics of Sheet-forming Operations
		Summary
		Key Terms
		Bibliography
		Review Questions
		Qualitative Problems
		Quantitative Problems
		Synthesis, Design, and Projects
	17 Powder-Metal Processing 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 Process Capabilities
		17.8 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
		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 Direct Manufacturing and Rapid Tooling
		Summary
		Key Terms
		Bibliography
		Review Questions
		Qualitative Problems
		Quantitative Problems
		Synthesis, Design, and Projects
Part 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
		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
Part 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 Wafer 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 and Nanoscale Manufacturing
		29.1 Introduction
		29.2 Micromachining of MEMS Devices
		29.3 The LIGA Microfabrication Process
		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
Part 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, 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
Part 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 Diamondlike 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
Part VIII: 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 and Inspection
		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
Part IX: Manufacturing in a Competitive Environment
	37 Automation of Manufacturing Processes
		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
		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 Process Selection in a Competitive Environment
		40.1 Introduction
		40.2 Product Design
		40.3 Product Quality and Life Expectancy
		40.4 Life-cycle Assessment and Sustainable Manufacturing
		40.5 Material Selection for Products
		40.6 Material Substitution
		40.7 Manufacturing Process Capabilities
		40.8 Process Selection
		40.9 Manufacturing Costs and Cost Reduction
		Summary
		Key Terms
		Bibliography
		Review Questions
		Qualitative Problems
		Synthesis, Design, and Projects
Index
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