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Manufacturing Processes for Engineering Materials / Edition 5

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Overview

Well organized and clearly written, this book uses a sound analytical approach to explain manufacturing processes; it enables the reader to understand and appreciate the complex interrelationships between the diverse topics in this field. The book carefully presents the fundamentals of materials processing along with their relevant applications, so that the reader can clearly assess the capabilities, limitations, and potentials of manufacturing processes and their competitive aspects. Using real-world examples and well-wrought graphics, this book covers a multitude of topics, including the mechanical behavior of materials; the structure and manufacturing properties of metals; surfaces, dimensional characteristics, inspection, and quality assurance; metal-casting processes including heat treatment; bulk deformation processes; sheet-metal forming processes; material removal processes; polymers, reinforced plastics, rapid prototyping and rapid tooling; metal powders, ceramics, glasses, composites, and superconductors; joining and fastening processes; microelectronic and micromechanical devices; automation; computer-integrated systems; and product design. For manufacturing engineers, metallurgists, industrial designers, material handlers, product designers, and quality assurance managers.
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Editorial Reviews

From The Critics
This engineering textbook describes the materials and processes commonly used for manufacturing products, with chapters on the properties of metals and polymers, heat treatment, joining and fastening, and automation of manufacturing systems. Case studies from industry illustrate the concepts. The fourth edition adds a chapter on the fabrication of microelectronic and micromechanical devices. Annotation c. Book News, Inc., Portland, OR
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Product Details

  • ISBN-13: 9780132272711
  • Publisher: Prentice Hall
  • Publication date: 7/31/2007
  • Series: Pearson Custom Library: Engineering Series
  • Edition description: New Edition
  • Edition number: 5
  • Pages: 976
  • Sales rank: 332,677
  • Product dimensions: 8.00 (w) x 10.00 (h) x 1.60 (d)

Meet the Author

Serope Kalpakjian taught and conducted research at the Illinois Institute of Technology for 38 years prior to his retirement in 2001 as professor emeritus of mechanical and materials engineering. After graduating from Robert College (high honors), Harvard University, and the Massachusetts Institute of Technology, he joined Cincinnati Milacron, where he was a research supervisor in advanced metal-forming processes. He is the author of numerous technical papers and several articles in handbooks and encyclopedias and has edited various conference proceedings. In addition, Professor Kalpakjian has served on the editorial bards of several journals and the Encyclopedia Americana and is the coauthor of Lubricants and Lubrication in Metalworking Operations. Both first editions of his textbooks, Manufacturing Processes for Engineering Materials and Manufacturing Engineering and Technology, have received the M. Eugene Merchant Manufacturing Textbook Award. He is a Life Fellow of the ASME, Fellow of the SME, Fellow and Life Member of ASM International, emeritus member of CIRP (International Institution for Production Engineering Research), and a founding member and past president of NAMRI/SME.

Among the awards Professor Kalpakjian has received are the Forging Industry Educational and Research Foundation Best Paper Award (1966), an Excellence in Teaching Award from IIT (1970), the Centennial Medallion from the ASME (1980), the International Education Award from the SME (1989), a Person of the Millennium Award from IIT (1999), and the Albert Easton White Distinguished Teacher Award from ASM International (2000). SME named the Outstanding YoungManufacturing Engineer Award after Professor Kalpakjian for the year 2002.

Steven R. Schmid is an associate professor with the Department of Aerospace and Mechanical Engineering, University of Notre Dame, where he teaches and performs research in the general areas of manufacturing, machine design, and tribology. As the director of the Manufacturing Tribology Laboratory at the university, he oversees industry- and government-funded research on a 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 the B.S. degree in mechanical engineering from the Illinois Institute of Technology (with honors) and M.S. and Ph.D. degrees, both in mechanical engineering, from Northwestern University. He has received numerous awards, including the John T Parsons Award from the SME (2000), the Newkirk Award from the ASME (2000), and the Kaneb Center Teaching Award (2000). He is the recipient of a National Science Foundation CAREERS Award (1996) and an ALCOA Foundation Award (1994). Dr. Schmid is the author of over 50 technical papers; has edited three conference proceedings; has coauthored two books, Fundamentals o f Machine Elements and Manufacturing Engineering and Tecbnology; and has contributed two chapters to the CRC Handbook of Modern Tribology. He serves on the Tribology Division Executive Committee of the ASME, is an associate editor of the Journal o f Manufacturing Science and Engineering, and is a registered professional engineer and certified manufacturing engineer.

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Table of Contents

1 Introduction 1

2 Fundamentals of the Mechanical Behavior of Materials 27

3 Structure and Manufacturing Properties of Metals 85

4 Surfaces, Tribology, Dimensional Characteristics, Inspection, and Product Quality Assurance 135

5 Metal-Casting Processes and Equipment; Heat Treatment 191

6 Bulk Deformation Processes 267

7 Sheet-Metal Forming Processes 351

8 Material-Removal Processes: Cutting 425

9 Material-Removal Processes: Abrasive, Chemical, Electrical, and High-Energy Beams 537

10 Properties and Processing of Polymers and Reinforced Plastics; Rapid Prototyping and Rapid Tooling 599

11 Properties and Processing of Metal Powders, Ceramics, Glasses, Composites, and Superconductors 687

12 Joining and Fastening Processes 753

13 Fabrication of Microelectronic, Micromechanical, and Microelectromechanical Devices; Nanomanufacturing 829

14 Automation of Manufacturing Processes and Operations 899

15 Computer-Integrated Manufacturing Systems 945

16 Product Design and Manufacturing in a Global Competitive Environment 985

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Preface

The fourth edition of this text, like the previous editions, continues to make an attempt at presenting a comprehensive, balanced, and up-to-date coverage of the relevant fundamentals and real-world applications of engineering materials and manufacturing processes and systems and the analytical approaches involved. The topics covered throughout the 16 chapters reflect the rapid and significant advances that have taken place in various areas in manufacturing, and they are organized and described in such a manner to draw the interest of students. The case studies, mostly from industry, make the subject of manufacturing science arr4engineering less abstract by showing students the practical aspects of process applications.

Integration of product design and manufacturing has justly resulted in greater recognition and prestige for these disciplines, and this edition therefore puts greater emphasis and better focus on this increasingly important subject. While studying this text, students should be able to assess the capabilities, limitations, and potential of production processes, including, particularly, the processes' economic and competitive aspects. The discussions throughout the chapters are aimed at motivating and challenging students to explore technically and economically viable solutions to a wide variety of important questions and problems in product design and manufacturing.

This book has been written mainly for undergraduate students in mechanical, industrial, and metallurgical and materials engineering programs; it is also useful for graduate courses in manufacturing science and engineering. The text, as well as the numerous examples and case studies ineach chapter, clearly shows that manufacturing engineering is an interdisciplinary and complex subject and that it is as important, exciting, and challenging as any other engineering discipline.

What's new in this edition

  • A new chapter has been added that covers the fabrication of microelectronic and micromechanical devices.
  • The discussion of design considerations in each chapter have been expanded.
  • Several new examples and case studies have been added throughout all chapters.
  • A total of 1230 questions and problems has been added-30% more than in the third edition.
  • Questions and problems now include a total of 140 design problems.
  • Figures have been improved for better graphical impact.
  • More cross-references to sections and chapters have been added throughout the text.
  • All chapter bibliographies have been thoroughly updated.

New or expanded topics for this edition include the following:

  • Automated guided vehicles
  • Biodegradable plastics
  • Cryogenic machining and grinding
  • Cryogenic treatment of cutting tools
  • Design considerations for casting
  • Design considerations for powder metallurgy
  • Design considerations for sheet-metal forming
  • Electrically conducting adhesives
  • Enterprise resource planning
  • Flexible fixturing
  • ISO 9000 and 14000 standards
  • Life-cycle assessment
  • LIGA process
  • Metal foams
  • Microelectromechanical systems fabrication
  • Microelectronics device fabrication
  • Micromachining
  • Modeling of casting
  • Nanomaterials
  • Plasma and wet etching
  • Polymer processing
  • Printed circuit boards
  • Rapid protoyping and rapid tooling
  • Rotary ultrasonic machining
  • Silicon microstructure
  • Six-sigma quality
  • Solid free-form fabrication
  • Stick-slip in extrusion
  • Superconductor processing
  • Surface-mount technology
  • Value assessment
  • Vibration and chatter in rolling
  • Water-jet peening
Read More Show Less

Introduction

The fourth edition of this text, like the previous editions, continues to make an attempt at presenting a comprehensive, balanced, and up-to-date coverage of the relevant fundamentals and real-world applications of engineering materials and manufacturing processes and systems and the analytical approaches involved. The topics covered throughout the 16 chapters reflect the rapid and significant advances that have taken place in various areas in manufacturing, and they are organized and described in such a manner to draw the interest of students. The case studies, mostly from industry, make the subject of manufacturing science arr4engineering less abstract by showing students the practical aspects of process applications.

Integration of product design and manufacturing has justly resulted in greater recognition and prestige for these disciplines, and this edition therefore puts greater emphasis and better focus on this increasingly important subject. While studying this text, students should be able to assess the capabilities, limitations, and potential of production processes, including, particularly, the processes' economic and competitive aspects. The discussions throughout the chapters are aimed at motivating and challenging students to explore technically and economically viable solutions to a wide variety of important questions and problems in product design and manufacturing.

This book has been written mainly for undergraduate students in mechanical, industrial, and metallurgical and materials engineering programs; it is also useful for graduate courses in manufacturing science and engineering. The text, as well as the numerous examples and case studies in each chapter,clearly shows that manufacturing engineering is an interdisciplinary and complex subject and that it is as important, exciting, and challenging as any other engineering discipline.

What's new in this edition

  • A new chapter has been added that covers the fabrication of microelectronic and micromechanical devices.
  • The discussion of design considerations in each chapter have been expanded.
  • Several new examples and case studies have been added throughout all chapters.
  • A total of 1230 questions and problems has been added-30% more than in the third edition.
  • Questions and problems now include a total of 140 design problems.
  • Figures have been improved for better graphical impact.
  • More cross-references to sections and chapters have been added throughout the text.
  • All chapter bibliographies have been thoroughly updated.

New or expanded topics for this edition include the following:

  • Automated guided vehicles
  • Biodegradable plastics
  • Cryogenic machining and grinding
  • Cryogenic treatment of cutting tools
  • Design considerations for casting
  • Design considerations for powder metallurgy
  • Design considerations for sheet-metal forming
  • Electrically conducting adhesives
  • Enterprise resource planning
  • Flexible fixturing
  • ISO 9000 and 14000 standards
  • Life-cycle assessment
  • LIGA process
  • Metal foams
  • Microelectromechanical systems fabrication
  • Microelectronics device fabrication
  • Micromachining
  • Modeling of casting
  • Nanomaterials
  • Plasma and wet etching
  • Polymer processing
  • Printed circuit boards
  • Rapid protoyping and rapid tooling
  • Rotary ultrasonic machining
  • Silicon microstructure
  • Six-sigma quality
  • Solid free-form fabrication
  • Stick-slip in extrusion
  • Superconductor processing
  • Surface-mount technology
  • Value assessment
  • Vibration and chatter in rolling
  • Water-jet peening
Read More Show Less

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