Manufacturing Processes for Engineering Materials

Description

For undergraduate courses in Mechanical, Industrial, Metallurgical, and Materials Engineering Programs. For graduate courses in Manufacturing Science and Engineering.   Manufacturing Processes for Engineering Materialsaddresses advances in all aspects of manufacturing, clearly presenting  comprehensive, up-to-date, and balanced coverage of the fundamentals of materials and processes. With the Sixth Edition, you'll learn to properly assess the capabilities, limitations, and potential of manufacturing processes and their competitive aspects. The authors present information that motivates and challenges for understanding and developing an appreciation of the vital importance of manufacturing in the modern global economy. The numerous examples and case studies throughout the book help to develop a perspective on the real-world applications of the topics described in the book. As in previous editions, this text maintains the same number of chapters while continuing to emphasize the interdisciplinary nature of all manufacturing activities, including the complex interactions among materials, design, and manufacturing processes. Cover Digital Resources for Students Title Page Copyright Dedication Contents Preface About the Authors Chapter 1. Introduction 1.1 What Is Manufacturing? 1.2 Product Design and Concurrent Engineering 1.3 Design for Manufacture, Assembly, Disassembly, and Service 1.4 Environmentally Conscious Design, Sustainable Manufacturing, and Product Life Cycle 1.5 Selecting Materials 1.6 Selecting Manufacturing Processes 1.7 Computer-Integrated Manufacturing 1.8 Lean Production and Agile Manufacturing 1.9 Quality Assurance and Total Quality Management 1.10 Manufacturing Costs and Global Competitiveness 1.11 General Trends in Manufacturing Chapter 2. Fundamentals of the Mechanical Behavior of Materials 2.1 Introduction 2.2 Tension 2.3 Compression 2.4 Torsion 2.5 Bending 2.6 Hardness 2.7 Fatigue 2.8 Creep 2.9 Impact 2.10 Residual Stresses 2.11 Yield Criteria 2.12 Work of Deformation Summary Bibliography Questions Problems Chapter 3. Structure and Manufacturing Properties of Metals 3.1 Introduction 3.2 The Crystal Structure of Metals 3.3 Deformation and Strength of Single Crystals 3.4 Grains and Grain Boundaries 3.5 Plastic Deformation of Polycrystalline Metals 3.6 Recovery, Recrystallization, and Grain Growth 3.7 Cold, Warm, and Hot Working 3.8 Failure and Fracture 3.9 Physical Properties 3.10 General Properties and Applications of Ferrous Alloys 3.11 General Properties and Applications of Nonferrous Metals and Alloys Summary Bibliography Questions Problems Chapter 4. Tribology, Metrology, and Product Quality 4.1 Introduction 4.2 Surface Structure and Properties 4.3 Surface Texture and Roughness 4.4 Tribology: Friction, Wear, and Lubrication 4.5 Surface Treatments, Coatings, and Cleaning 4.6 Engineering Metrology and Instrumentation 4.7 Dimensional Tolerances 4.8 Testing and Inspection 4.9 Quality Assurance Summary Bibliography Questions Problems Chapter 5. Casting Processes and Heat Treatment 5.1 Introduction 5.2 Solidification of Metals 5.3 Cast Structures 5.4 Fluid Flow and Heat Transfer 5.5 Melting Practice and Furnaces 5.6 Casting Alloys 5.7 Ingot Casting and Continuous Casting 5.8 Expendable-Mold, Permanent-Pattern Casting Processes 5.9 Expendable-Mold, Expendable-Pattern Casting Processes 5.10 Permanent-Mold Casting Processes 5.11 Heat Treatment 5.12 Design Considerations 5.13 Economics of Casting Summary Bibliography Questions Problems Design Chapter 6. Bulk Deformation Processes 6.1 Introduction 6.2 Forging 6.3 Rolling 6.4 Extrusion 6.5 Rod, Wire, and Tube Drawing 6.6 Swaging 6.7 Die-Manufacturing Methods 6.8 Die Failures 6.9 Economics of Bulk Forming Summary Bibliography Questions Problems Design Chapter 7. Sheet Metal Processes 7.1 Introduction 7.2 Sheet Metal Characteristics 7.3 Shearing 7.4 Bending of Sheet and Plate 7.5 Miscellaneous Forming Processes 7.6 Deep Drawing 7.7 Sheet Metal Formability 7.8 Equipment for Sheet Metal Forming 7.9 Design Considerations 7.10 Economics of Sheet Metal Forming Summary Bibliography Questions Problems Design Chapter 8. Machining Processes 8.1 Introduction 8.2 Mechanics of Chip Formation 8.3 Tool Wear and Failure 8.4 Surface Finish and Surface Integrity 8.5 Machinability 8.6 Cutting-Tool Materials 8.7 Cutting Fluids 8.8 High-Speed Machining 8.9 Cutting Processes and Machine Tools for Producing Round Shapes 8.10 Cutting Processes and Machine Tools for Producing Various Shapes 8.11 Machining and Turning Centers 8.12 Vibration and Chatter 8.13 Machine-Tool Structures 8.14 Design Considerations 8.15 Economics of Machining Summary Bibliography Questions Problems Design Chapter 9. Abrasive and Other Material Removal Processes 9.1 Introduction 9.2 Abrasives 9.3 Bonded Abrasives 9.4 Mechanics of Grinding 9.5 Grinding-Wheel Wear 9.6 Grinding Operations and Machines 9.7 Finishing Operations 9.8 Deburring 9.9 Ultrasonic Machining 9.10 Chemical Machining 9.11 Electrochemical Machining 9.12 Electrochemical Grinding 9.13 Electrical-Discharge Machining 9.14 High-Energy-Beam Machining 9.15 Water-Jet, Abrasive Water-Jet, and Abrasive-Jet Machining 9.16 Hybrid Machining Systems 9.17 Design Considerations 9.18 Process Economics Summary Bibliography Questions Problems Design Chapter 10. Polymer Processing and Additive Manufacturing 10.1 Introduction 10.2 The Structure of Polymers 10.3 Thermoplastics: Behavior and Properties 10.4 Thermosets: Behavior and Properties 10.5 Thermoplastics: General Characteristics and Applications 10.6 Thermosets: General Characteristics and Applications 10.7 High-Temperature Polymers, Electrically Conducting Polymers, and Biodegradable Plastics 10.8 Elastomers (Rubbers): General Characteristics and Applications 10.9 Reinforced Plastics 10.10 Processing of Plastics 10.11 Processing of Polymer-Matrix-Reinforced Plastics 10.12 Additive Manufacturing 10.13 Design Considerations 10.14 Economics of Processing Plastics Summary Bibliography Questions Problems Design Chapter 11. Powder Metallurgy and Processing of Ceramics and Glasses 11.1 Introduction 11.2 Powder Metallurgy 11.3 Compaction of Metal Powders 11.4 Sintering 11.5 Secondary and Finishing Operations 11.6 Design Considerations for Powder Metallurgy 11.7 Economics of Powder Metallurgy 11.8 Ceramics: Structure, Properties, and Applications 11.9 Shaping Ceramics 11.10 Glasses: Structure, Properties, and Applications 11.11 Forming and Shaping Glass 11.12 Design Considerations for Ceramic and Glass Products 11.13 Graphite and Diamond 11.14 Processing Metal-Matrix and Ceramic-Matrix Composites 11.15 Processing Superconductors Summary Bibliography Questions Problems Design Chapter 12. Joining and Fastening Processes 12.1 Introduction 12.2 Oxyfuel Gas Welding 12.3 Arc Welding Processes: Consumable Electrode 12.4 Arc Welding Processes: Nonconsumable Electrode 12.5 High Energy Beam Welding 12.6 Cutting 12.7 The Fusion Welded Joint 12.8 Cold Welding 12.9 Ultrasonic Welding 12.10 Friction Welding 12.11 Resistance Welding 12.12 Explosion Welding 12.13 Diffusion Bonding 12.14 Brazing and Soldering 12.15 Adhesive Bonding 12.16 Mechanical Fastening 12.17 Joining Nonmetallic Materials 12.18 Design Considerations in Joining 12.19 Economic Considerations Summary Bibliography Questions Problems Design Chapter 13. Micro- and Nanomanufacturing 13.1 Introduction 13.2 Clean Rooms 13.3 Semiconductors and Silicon 13.4 Crystal Growing and Wafer Preparation 13.5 Films and Film Deposition 13.6 Oxidation 13.7 Lithography 13.8 Etching 13.9 Diffusion and Ion Implantation 13.10 Metallization and Testing 13.11 Wire Bonding and Packaging 13.12 Yield and Reliability of Chips 13.13 Printed Circuit Boards 13.14 Roll-to-Roll Printing of Flexible Electronics 13.15 Micromachining of MEMS Devices 13.16 LIGA and Related Microfabrication Processes 13.17 Solid Freeform Fabrication of Devices 13.18 Mesoscale Manufacturing 13.19 Nanoscale Manufacturing Summary Bibliography Questions Problems Design Chapter 14. Automation of Manufacturing Processes and Operations 14.1 Introduction 14.2 Automation 14.3 Numerical Control 14.4 Programming for Numerical Control 14.5 Adaptive Control 14.6 Material Handling and Movement 14.7 Industrial Robots 14.8 Sensor Technology 14.9 Flexible Fixturing 14.10 Assembly, Disassembly, and Service 14.11 Design Considerations 14.12 Economic Considerations Summary Bibliography Questions Problems Design Chapter 15. Computer-Integrated Manufacturing Systems 15.1 Introduction 15.2 Manufacturing Systems 15.3 Computer-Integrated Manufacturing 15.4 Computer-Aided Design and Engineering 15.5 Computer-Aided Manufacturing 15.6 Computer-Aided Process Planning 15.7 Computer Simulation of Manufacturing Processes and Systems 15.8 Group Technology 15.9 Cellular Manufacturing 15.10 Flexible Manufacturing Systems 15.11 Holonic Manufacturing 15.12 Just-in-Time Production 15.13 Lean Manufacturing 15.14 Communications Networks in Manufacturing 15.15 Artificial Intelligence in Manufacturing Summary Bibliography Questions Problems Design Chapter 16. Competitive Aspects of Product Design and Manufacturing 16.1 Introduction 16.2 Product Design and Robust Design 16.3 Product Quality as a Manufacturing Goal 16.4 Life-Cycle Assessment and Sustainable Manufacturing 16.5 Energy Consumption in Manufacturing 16.6 Selection of Materials for Products 16.7 Substitution of Materials in Products 16.8 Capabilities of Manufacturing Processes 16.9 Selection of Manufacturing Processes 16.10 Manufacturing Costs and Cost Reduction Summary Bibliography Questions Problems Design Answers to Selected Problems Index A B C D E F G H I J K L M N O P Q R S T U V W X Y Z