Manufacturing Processes for Engineering Materials / Edition 2

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Overview

The text has been written for students in mechanical, manufacturing, industrial, chemical, and metallurgical and materials engineering programs. It is hoped that in reading and studying this text, students will appreciate the importance and relevance of manufacturing engineering as a subject that is as exciting and challenging as any other engineering discipline.
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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: 9780201508062
  • Publisher: Addison-Wesley
  • Publication date: 6/28/1991
  • Series: Mechanical Engineering Series
  • Edition description: 2nd ed
  • Edition number: 2
  • Pages: 944
  • Product dimensions: 7.74 (w) x 9.41 (h) x 1.59 (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

Preface xiii
1 Introduction 1
1.1 What Is Manufacturing? 1
1.2 Product Design and Concurrent Engineering 6
1.3 Design for Manufacture, Assembly, Disassembly, and Service 8
1.4 Environmentally Conscious Design and Manufacturing 10
1.5 Selecting Materials 11
1.6 Selecting Manufacturing Processes 14
1.7 Computer-Integrated Manufacturing 17
1.8 Quality Assurance and Total Quality Management 20
1.9 Product Liability 21
1.10 Manufacturing Costs, Lean Production, and Agile Manufacturing 22
1.11 General Trends in Manufacturing 23
1.12 Responsibilities of Manufacturing Engineers 24
2 Fundamentals of the Mechanical Behavior of Materials 26
2.1 Introduction 26
2.2 Tension 27
2.3 Compression 43
2.4 Torsion 46
2.5 Bending 48
2.6 Hardness 49
2.7 Fatigue 54
2.8 Creep 55
2.9 Impact 56
2.10 Residual Stresses 57
2.11 Triaxial Stresses and Yield Criteria 60
2.12 Work of Deformation 68
3 Structure and Manufacturing Properties of Metals 81
3.1 Introduction 81
3.2 The Crystal Structure of Metals 82
3.3 Deformation and Strength of Single Crystals 83
3.4 Grains and Grain Boundaries 89
3.5 Plastic Deformation of Polycrystalline Metals 92
3.6 Recovery, Recrystallization, and Grain Growth 93
3.7 Cold, Warm, and Hot Working 95
3.8 Failure and Fracture 96
3.9 Physical Properties 103
3.10 Properties and Applications of Ferrous Alloys 108
3.11 Properties and Applications of Nonferrous Metals and Alloys 112
4 Surfaces, Tribology, Dimensional Characteristics, Inspection, and Product Quality Assurance 128
4.1 Introduction 128
4.2 Surface Structure and Properties 129
4.3 Surface Texture 130
4.4 Tribology: Friction, Wear, and Lubrication 134
4.5 Surface Treatments, Coatings, and Cleaning 151
4.6 Engineering Metrology and Instrumentation 160
4.7 Dimensional Tolerances 165
4.8 Testing and Inspection 167
4.9 Quality Assurance 170
5 Metal-Casting Processes and Equipment; Heat Treatment 186
5.1 Introduction 186
5.2 Solidification of Metals 187
5.3 Cast Structures 195
5.4 Fluid Flow and Heat Transfer 199
5.5 Melting Practice and Furnaces 207
5.6 Casting Alloys 209
5.7 Ingot Casting and Continuous Casting 215
5.8 Casting Processes: Expendable Mold, Permanent Pattern 218
5.9 Casting Processes: Expendable Mold, Expendable Pattern 224
5.10 Casting Processes: Permanent Mold 227
5.11 Heat Treatment 235
5.12 Design Considerations 245
5.13 Economics of Casting 249
6 Bulk Deformation Processes 260
6.1 Introduction 260
6.2 Forging 260
6.3 Rolling 282
6.4 Extrusion 300
6.5 Rod, Wire, and Tube Drawing 312
6.6 Swaging 321
6.7 Die Manufacturing Methods 322
6.8 Die Failures 324
7 Sheet-Metal Forming Processes 336
7.1 Introduction 336
7.2 Sheet-Metal Characteristics 336
7.3 Shearing 341
7.4 Bending of Flat Sheet and Plate 349
7.5 Stretch Forming 360
7.6 Bulging 362
7.7 Rubber Forming and Hydroforming 363
7.8 Spinning 364
7.9 High-Energy-Rate Forming 368
7.10 Superplastic Forming 371
7.11 Various Forming Methods 372
7.12 Deep Drawing 374
7.13 Formability of Sheet Metals 385
7.14 Equipment for Sheet-Metal Forming 391
7.15 Design Considerations 392
7.16 Economics of Sheet-Metal Forming 394
8 Material-Removal Processes: Cutting 404
8.1 Introduction 404
8.2 Mechanics of Chip Formation 405
8.3 Tool Wear and Failure 426
8.4 Surface Finish and Integrity 434
8.5 Machinability 437
8.6 Cutting-Tool Materials 440
8.7 Cutting Fluids 451
8.8 Cutting Processes and Machine Tools for Producing Round Shapes 454
8.9 Cutting Processes and Machine Tools for Producing Various Shapes 468
8.10 Machining and Turning Centers 482
8.11 Vibration and Chatter 486
8.12 Machine-Tool Structures 488
8.13 Design Considerations 489
8.14 Economics of Machining 490
9 Material Removal Processes: Abrasive, Chemical, Electrical, and High-Energy Beams 504
9.1 Introduction 504
9.2 Abrasives 505
9.3 Bonded Abrasives 506
9.4 Mechanics of Grinding 510
9.5 Grinding-Wheel Wear 517
9.6 Grinding Operations and Machines 521
9.7 Ultrasonic Machining 527
9.8 Finishing Operations 528
9.9 Deburring 532
9.10 Chemical Machining 533
9.11 Electrochemical Machining 537
9.12 Electrochemical Grinding 539
9.13 Electrical-Discharge Machining 540
9.14 High-Energy-Beam Machining 544
9.15 Water-Jet, Abrasive Water-Jet, and Abrasive-Jet Machining 547
9.16 Design Considerations 549
9.17 Process Economics 549
10 Properties and Processing of Polymers and Reinforced Plastics; Rapid Prototyping and Rapid Tooling 559
10.1 Introduction 559
10.2 The Structure of Polymers 560
10.3 Thermoplastics: Behavior and Properties 568
10.4 Thermosets: Behavior and Properties 575
10.5 Thermoplastics: General Characteristics and Applications 576
10.6 Thermosets: General Characteristics and Applications 578
10.7 High-Temperature Polymers, Electrically Conducting Polymers, and Biodegradable Plastics 579
10.8 Elastomers (Rubbers): General Characteristics and Applications 581
10.9 Reinforced Plastics 582
10.10 Processing of Plastics 590
10.11 Processing of Polymer-Matrix-Reinforced Plastics 605
10.12 Rapid Prototyping and Rapid Tooling 610
10.13 Design Considerations 619
10.14 Economics of Processing Plastics 621
11 Properties and Processing of Metal Powders, Ceramics, Glasses, Composites, and Superconductors 630
11.1 Introduction 630
11.2 Production of Metal Powders 631
11.3 Compaction of Metal Powders 636
11.4 Sintering 644
11.5 Secondary and Finishing Operations 649
11.6 Design Considerations for Powder Metallurgy 651
11.7 Economics of Powder Metallurgy 653
11.8 Ceramics: Structure, Properties, and Applications 655
11.9 Shaping Ceramics 663
11.10 Glasses: Structure, Properties, and Applications 668
11.11 Forming and Shaping Glass 671
11.12 Design Considerations for Ceramics and Glasses 675
11.13 Graphite and Diamond 675
11.14 Processing Metal-Matrix and Ceramic-Matrix Composites 676
11.15 Processing Superconductors 679
12 Joining and Fastening Processes 688
12.1 Introduction 688
12.2 Arc-Welding Processes: Consumable Electrode 690
12.3 Arc-Welding Processes: Nonconsumable Electrode 697
12.4 High-Energy-Beam Welding 699
12.5 The Fusion-Welded Joint 701
12.6 Cold Welding 712
12.7 Ultrasonic Welding 713
12.8 Friction Welding 714
12.9 Resistance Welding 716
12.10 Explosion Welding 721
12.11 Diffusion Bonding 722
12.12 Brazing and Soldering 723
12.13 Adhesive Bonding 730
12.14 Mechanical Fastening 734
12.15 Joining Plastics, Ceramics, and Glasses 737
12.16 Design Considerations in Joining 740
12.17 Economic Considerations 743
13 Fabrication of Microelectronic and Micromechanical Devices 753
13.1 Introduction 753
13.2 Semiconductors and Silicon 756
13.3 Crystal Growing and Wafer Preparation 757
13.4 Films and Film Deposition 759
13.5 Oxidation 761
13.6 Lithography 762
13.7 Diffusion and Ion Implantation 765
13.8 Etching 766
13.9 Metallization and Testing 776
13.10 Wire Bonding and Packaging 778
13.11 Yield and Reliability of Chips 781
13.12 Printed Circuit Boards 782
13.13 Micromachining of MEMS Devices 785
13.14 The LIGA Microfabrication Process 794
13.15 Solid Free-Form Fabrication of Devices 799
14 Automation of Manufacturing Processes and Systems 808
14.1 Introduction 808
14.2 Automation 809
14.3 Numerical Control 815
14.4 Programming for Numerical Control 821
14.5 Adaptive Control 822
14.6 Material Handling and Movement 825
14.7 Industrial Robots 827
14.8 Sensor Technology 833
14.9 Flexible Fixturing 837
14.10 Assembly, Disassembly, and Service 839
14.11 Design Considerations 842
14.12 Economic Considerations 845
15 Computer-Integrated Manufacturing Systems 852
15.1 Introduction 852
15.2 Manufacturing Systems 853
15.3 Computer-Integrated Manufacturing 854
15.4 Computer-Aided Design and Engineering 856
15.5 Computer-Aided Manufacturing 861
15.6 Computer-Aided Process Planning 861
15.7 Computer Simulation of Manufacturing Processes and Systems 864
15.8 Group Technology 866
15.9 Cellular Manufacturing 872
15.10 Flexible Manufacturing Systems 874
15.11 Just-in-Time Production 876
15.12 Communications Networks in Manufacturing 878
15.13 Artificial Intelligence 880
15.14 The Factory of the Future 883
15.15 Economic Considerations 885
16 Product Design and Competitive Aspects of Manufacturing 893
16.1 Introduction 893
16.2 Product Design and Robust Design 894
16.3 Product Quality and Life Expectancy 898
16.4 Life-Cycle Assessment, Life-Cycle Engineering, and Sustainable Manufacturing 899
16.5 Selection of Materials for Products 901
16.6 Substitution of Materials in Products 905
16.7 Capabilities of Manufacturing Processes 907
16.8 Selection of Manufacturing Processes 911
16.9 Manufacturing Costs and Cost Reduction 915
16.10 Value Analysis 919
Index 928
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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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