Manufacturing Engineering & Technology / Edition 6

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Overview

FEATURES/BENEFITS

  • NEW—New chapter on Rapid Prototyping (Ch. 19).
  • NEW—Every chapter has been reviewed and updated. Every bibliography has been revised, new examples from industry have been added, and over 30% of the problems are new.
  • Superior use of analogies, discussions and problems.
    • Motivates interest in the subject.
  • Excellent overview of manufacturing concepts is provided with a balance of relevant fundamentals and real-world practice.
  • Covers the latest technological advances—Such as abrasive machining, nanofabrication, rapid tooling and semisolid metalworking.
  • Contains four kinds of EOC problems—Review Questions, Qualitative Problems, Quantitative Problems, and Synthesis and Design Problems.
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Editorial Reviews

Booknews
New edition of a text that provides balanced coverage of relevant fundamentals and real-world practices so that the student can understand the important and often complex interrelationships among the many technical and economic factors involved in manufacturing. In the 40 chapters, Kalpakjian (Illinois Institute of Technology) and Schmid (aerospace and mechanical engineering, U. of Notre Dame) discuss fundamentals of materials (their behavior and manufacturing properties), metal-casting processes and equipment, forming and shaping processes and equipment, material-removal processes and machines, joining processes and equipment, surface technology, common aspects of manufacturing, and manufacturing in a competitive environment. Illustrated with b&w charts and drawings. Annotation c. Book News, Inc., Portland, OR (booknews.com)
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Product Details

  • ISBN-13: 9780136081685
  • Publisher: Prentice Hall
  • Publication date: 4/10/2009
  • Edition description: Older Edition
  • Edition number: 6
  • Pages: 1200
  • Product dimensions: 8.20 (w) x 10.10 (h) x 1.90 (d)

Meet the Author

Professor Serope Kalpakjian has been teaching at the Illinois Institute of Technology since 1963. After graduating from Robert College (with High Honors), Harvard University, and the Massachusetts Institute of Technology, he joined Cincinnati Milacron, Inc., where he was a research supervisor in charge of advanced metal-forming processes. He has published numerous papers and is the author of several articles in encyclopedias and handbooks; he has also edited various volumes and serves on the editorial boards of several journals and the Encyclopedia Americana.

He is the author of three additional manufacturing books, two of which received the M. Eugene Merchant Manufacturing Textbook Award. He is a Life Fellow of the American Society of Mechanical Engineers, Fellow and Life Member of ASM International, and Fell of the Society of Manufacturing Engineers, and is a full member (Emeritus) of the International Institution for Production Engineering Research (CIRP). He is a founding member and a past president of the North American manufacturing Research Institution.

Professor Kalpakjian has received several awards: Citation by the Forging Industry Educational and Research Foundation for best paper (1966); Citation by the Society of Carbide and Tool Engineers (1977); The "Excellence in Teaching Award" from the Illinois Institute of Technology (1970); the "Centennial Medallion" by the American Society of Mechanical Engineers (1980); the International "Education Award" by the Society of Manufacturing Engineers (1989); and the Albert Easton White Distinguished Teacher Award by the American Society for Metals International (2000).

Dr. Steven R. Schmid is an Associate Professor in the Department of Aerospace and Mechanical Engineering at the University of Notre Dame, where he teaches and conducts research in manufacturing, machine design, and tribology. As the Director of the Manufacturing Tribology Laboratory at the university, he oversees industry and governmentally funded research on a wide variety of manufacturing topics, including tribological issues in rolling, forging and sheet metal forming, polymer processing, medical device design and manufacture, and nanomechanics.

He received his Bachelor's degree in Mechanical Engineering from the Illinois Institute of Technology (with Honors) and Master's and Ph.D. degrees, both in Mechanical Engineering, from Northwestern University. Dr. Schmid is the recipient of a National Science Foundation CAREERS Award and an ALCOA Foundation Young Faculty Award. He has been a leading proponent for the integration of research and engineering education; NSF has sponsored workshops on this issue for which he has served as head of the steering committee.

He is the author of over thirty technical papers in various journals, has edited three conference proceedings, has co-authored "Fundamentals of Machine Elements," and has contributed two chapters to the CRC "Handbook of Modern Tribology." He serves on the Tribology Division Executive Committee of the American Society of Mechanical Engineers, and has held officer positions in the Society of Manufacturing Engineers and the Society of Tribology and Lubrication Engineers. He is a registered Professional Engineer an a Certified Manufacturing Engineer

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Read an Excerpt

PREFACE:

Preface

The field of manufacturing engineering and technology continues to advance rapidly, transcending disciplines and driving economic growth. This challenging and broad topic has continued to incorporate new concepts at an increasing rate, making manufacturing a dynamic and exciting field of study. In preparing this fourth edition, our most important goal throughout has been to provide a comprehensive state-of-the-art textbook on manufacturing, which also encompasses the additional aims of motivating and challenging students.

As in previous editions, the text presents topics with a balanced coverage of relevant fundamentals and real-world practices, so that the student develops an understanding of the important and often complex interrelationships among the many technical and economic factors involved in manufacturing.

This new edition basically follows the same introductory nature, format, organization, and balance as the third edition. It has retained its emphasis on (a) the influence of materials and processing parameters in understanding manufacturing processes and operations; (b) design considerations, product quality, and manufacturing cost factors; and (c) the domestic and global competitive context of each manufacturing process and operation, highlighted with illustrative examples.

STUDY AIDS

  • Presentation of each topic within a larger context of manufacturing engineering and technology, using extensive schematic diagrams and flowcharts.
  • Emphasis on the practical uses of the concepts and information presented.
  • Analogies, discussions, and problems designed to stimulate the student'scuriosity about consumer and industrial products and how they are manufactured.
  • Extensive reference material, including numerous tables, illustrations, graphs, and bibliographies.
  • Numerous illustrative examples and case studies to highlight important concepts and techniques.
  • Tables comparing advantages and limitations of manufacturing processes.
  • A summary, list of key terms, and concise description of current trends at the end of each chapter.

WHAT IS NEW IN THIS EDITION

  • Several new examples and case studies have been added.
  • There are now a total of almost 2,200 questions and problems, about a quarter of them new to this edition.
  • Summaries at the end of each chapter have been completely rewritten and expanded.
  • The bibliographies at the end of each chapter have been thoroughly updated.
  • More cross-references have been made throughout the text to other sections and chap ters in the book.
  • New or expanded topics include the following:
  • Abrasive belts; microreplication
  • Atomic force microscope
  • Biodegradable plastics
  • Bundle drawing
  • Carbon foam
  • Chemical mechanical polishing
  • Coatings
  • Compliant end effector
  • Conductive graphite fibers
  • Deburring
  • Diamond-like carbon coating
  • Die failures
  • Die manufacturing methods
  • Electrically conducting adhesives
  • Friction stir welding
  • Hexapod machine tools
  • ISO 14000 standard
  • Joining plastics
  • Laser interferometry
  • Laser peening
  • Linear motor drives for machine tools
  • Microencapsulated powders
  • Microgram carbides
  • Micromachining
  • Nanofabrication
  • Nanomaterials
  • Nanopowders
  • Octree representation
  • Overmolding
  • Plastics, common trade names
  • Porous aluminum
  • Product liability examples
  • Pulsed electrochemical machining
  • QS 9000 standard
  • Rapid prototyping
  • Reflow soldering
  • Robustness
  • Rotary ultrasonic machining
  • Superconductor processing
  • Taguchi loss function
  • Thermal effects in machine tools
  • Titanic: brittle fracture example
  • Total productive maintenance
  • Transfer/injection molding
  • Water-jet peening
  • Wave soldering

In response to comments and suggestions by numerous reviewers, several major and minor changes have also been made throughout the text. A page-by-page comparison with the third edition will show that literally thousands of changes have been made for improved clarity and completeness.

AUDIENCE

As in the previous editions, this fourth edition has been written for students in mechanical, manufacturing, industrial, aerospace, and metallurgical and materials engineering programs. It is hoped that by reading and studying this book, students will come to appreciate the vital nature of manufacturing engineering as an academic subject that is as exciting, challenging, and important as any other engineering and technology discipline.

Read More Show Less

Table of Contents

General Introduction 1
 
Part. I Fundamentals of Materials: Their Behavior and Manufacturing Properties 39
1 The Structure of Metals 43
2 Mechanical Behavior, Testing, and Manufacturing Properties of Materials 61
3 Physical Properties of Materials 103
4 Metal Alloys: Their Structure and Strengthening by Heat Treatment 114
5 Steels: Production, General Properties, and Applications 152
6 Nonferrous Metals and Alloys: Production, General Properties, and Applications 176
7 Polymers: Structure, General Properties, and Applications 198
8 Ceramics, Graphite, and Diamond: Structure, General Properties, and Applications 225
9 Composite Materials: Structure, General Properties, and Applications 242
 
Part. II Metal-Casting Processes and Equipment 261
10 Fundamentals of Metal Casting 265
11 Metal-Casting Processes 287
12 Casting Design, Materials, and Economics 334
 
Part. III Forming and Shaping Processes and Equipment 353
13 Rolling 357
14 Forging 381
15 Extrusion and Drawing 417
16 Sheet-Metal Forming 444
17 Powder Metallurgy 499
18 Forming and Shaping Plastics and Composite Materials; Rapid Prototyping 529
19 Forming and Shaping Ceramics and Glass 573
 
Part. IV Material-Removal Processes and Machines 589
20 Fundamentals of Cutting 594
21 Cutting-Tool Materials and Cutting Fluids 635
22 Machining Processor for Producing Round Shapes 662
23 Machining Processes for Producing Various Shapes 716
24 Machining and Turning Centers, Machine-Tool Structures, and Machining Economics 758
25 Abrasive Machining and Finishing Operations 781
26 Nontraditional Machining Processes 825
 
Part. V Joining Processes and Equipment 853
27 Fusion Welding Processes 858
28 Solid-State Welding Processes 885
29 The Metallurgy of Welding; Welding Design and Process Selection 908
30 Brazing, Soldering, Adhesive Bonding, and Mechanical Fastening Processes 928
 
Part. VI Surface Technology 953
31 Surfaces: Their Nature, Roughness, and Measurement 957
32 Tribology: Friction, Wear, and Lubrication 969
33 Surface Treatment, Coating, and Cleaning 990
34 Fabrication of Microelectronic Devices 1012
 
Part. VII Common Aspects of Manufacturing 1033
35 Engineering Metrology and Instrumentation 1035
36 Quality Assurance, Testing, and Inspection 1068
37 Human-Factors Engineering, Safety, and Product Liability 1100
 
Part. VIII Manufacturing in a Competitive Environment 1115
38 Automation of Manufacturing Processes 1118
39 Computer-Integrated Manufacturing Systems 1171
40 Competitive Aspects of Manufacturing 1216
Index 1245
Read More Show Less

Preface

PREFACE:

Preface

The field of manufacturing engineering and technology continues to advance rapidly, transcending disciplines and driving economic growth. This challenging and broad topic has continued to incorporate new concepts at an increasing rate, making manufacturing a dynamic and exciting field of study. In preparing this fourth edition, our most important goal throughout has been to provide a comprehensive state-of-the-art textbook on manufacturing, which also encompasses the additional aims of motivating and challenging students.

As in previous editions, the text presents topics with a balanced coverage of relevant fundamentals and real-world practices, so that the student develops an understanding of the important and often complex interrelationships among the many technical and economic factors involved in manufacturing.

This new edition basically follows the same introductory nature, format, organization, and balance as the third edition. It has retained its emphasis on (a) the influence of materials and processing parameters in understanding manufacturing processes and operations; (b) design considerations, product quality, and manufacturing cost factors; and (c) the domestic and global competitive context of each manufacturing process and operation, highlighted with illustrative examples.

STUDY AIDS

  • Presentation of each topic within a larger context of manufacturing engineering and technology, using extensive schematic diagrams and flowcharts.
  • Emphasis on the practical uses of the concepts and information presented.
  • Analogies, discussions, and problems designed to stimulate thestudent'scuriosity about consumer and industrial products and how they are manufactured.
  • Extensive reference material, including numerous tables, illustrations, graphs, and bibliographies.
  • Numerous illustrative examples and case studies to highlight important concepts and techniques.
  • Tables comparing advantages and limitations of manufacturing processes.
  • A summary, list of key terms, and concise description of current trends at the end of each chapter.

WHAT IS NEW IN THIS EDITION

  • Several new examples and case studies have been added.
  • There are now a total of almost 2,200 questions and problems, about a quarter of them new to this edition.
  • Summaries at the end of each chapter have been completely rewritten and expanded.
  • The bibliographies at the end of each chapter have been thoroughly updated.
  • More cross-references have been made throughout the text to other sections and chap ters in the book.
  • New or expanded topics include the following:
  • Abrasive belts; microreplication
  • Atomic force microscope
  • Biodegradable plastics
  • Bundle drawing
  • Carbon foam
  • Chemical mechanical polishing
  • Coatings
  • Compliant end effector
  • Conductive graphite fibers
  • Deburring
  • Diamond-like carbon coating
  • Die failures
  • Die manufacturing methods
  • Electrically conducting adhesives
  • Friction stir welding
  • Hexapod machine tools
  • ISO 14000 standard
  • Joining plastics
  • Laser interferometry
  • Laser peening
  • Linear motor drives for machine tools
  • Microencapsulated powders
  • Microgram carbides
  • Micromachining
  • Nanofabrication
  • Nanomaterials
  • Nanopowders
  • Octree representation
  • Overmolding
  • Plastics, common trade names
  • Porous aluminum
  • Product liability examples
  • Pulsed electrochemical machining
  • QS 9000 standard
  • Rapid prototyping
  • Reflow soldering
  • Robustness
  • Rotary ultrasonic machining
  • Superconductor processing
  • Taguchi loss function
  • Thermal effects in machine tools
  • Titanic: brittle fracture example
  • Total productive maintenance
  • Transfer/injection molding
  • Water-jet peening
  • Wave soldering

In response to comments and suggestions by numerous reviewers, several major and minor changes have also been made throughout the text. A page-by-page comparison with the third edition will show that literally thousands of changes have been made for improved clarity and completeness.

AUDIENCE

As in the previous editions, this fourth edition has been written for students in mechanical, manufacturing, industrial, aerospace, and metallurgical and materials engineering programs. It is hoped that by reading and studying this book, students will come to appreciate the vital nature of manufacturing engineering as an academic subject that is as exciting, challenging, and important as any other engineering and technology discipline.

Read More Show Less

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