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Preface | |
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About the Authors | |
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General Introduction | |
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What is Manufacturing? | |
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Examples of Manufactured Products | |
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The Design Process and Concurrent Engineering | |
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Design for Manufacture, Assembly, Disassembly, and Service | |
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Selecting Materials | |
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Selecting Manufacturing Processes | |
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Computer-Integrated Manufacturing | |
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Quality Assurance and Total Quality Management | |
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Global Competitiveness and Manufacturing Costs | |
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Lean Production and Agile Manufacturing | |
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Environmentally-Conscious Design and Manufacturing | |
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Product Liability | |
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Organization for Manufacture | |
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Fundamentals of Materials: Their Behavior and Manufacturing Properties | |
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The Structure of Metals | |
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Introduction | |
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The Crystal Structure of Metals | |
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Deformation and Strength of Single Crystals | |
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Grains and Grain Boundaries | |
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Plastic Deformation of Polycrystalline Metals | |
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Recovery, Recrystallization, and Grain Growth | |
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Cold-, Warm-, and Hot-Working | |
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Mechanical Behavior, Testing, and Manufacturing Properties of Materials | |
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Introduction | |
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Tension | |
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Compression | |
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Torsion | |
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Bending (Flexure) | |
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Hardness | |
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Fatigue | |
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Creep | |
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Impact | |
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Failure and Fracture of Materials in Manufacturing and Service | |
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Residual Stresses | |
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Work, Heat, and Temperature | |
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Physical Properties of Materials | |
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Introduction | |
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Density | |
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Melting Point | |
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Specific Heat | |
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Thermal Conductivity | |
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Thermal Expansion | |
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Electrical, Magnetic, and Optical Properties | |
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Corrosion Resistance | |
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Metal Alloys: Their Structure and Strengthening by Heat Treatment | |
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Introduction | |
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Structure of Alloys | |
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Phase Diagrams | |
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The Iron-Carbon System | |
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The Iron-Iron Carbide Phase Diagram and the Development of Microstructures in Steels | |
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Cast Irons | |
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Heat Treatment of Ferrous Alloys | |
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Hardenability of Ferrous Alloys | |
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Heat Treatment of Nonferrous Alloys and of Stainless Steels | |
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Case Hardening | |
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Annealing | |
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Heat-Treating Furnaces and Equipment | |
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Design Considerations for Heat Treating | |
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Ferrous Metals and Alloys: Production, General Properties and Applications | |
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Introduction | |
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Production of Iron and Steel | |
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Casting of Ingots | |
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Continuous Casting | |
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Carbon and Alloy Steels | |
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Stainless Steels | |
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Tool and Die Steels | |
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Nonferrous Metals and Alloys: Production, General Properties, and Applications | |
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Introduction | |
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Aluminum and Aluminum Alloys | |
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Magnesium and Magnesium Alloys | |
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Copper and Copper Alloys | |
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Nickel and Nickel Alloys | |
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Superalloys | |
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Titanium and Titanium Alloys | |
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Refractory Metals and Alloys | |
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Beryllium | |
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Zirconium | |
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Low-melting Alloys | |
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Precious Metals | |
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Shape-Memory Alloys | |
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Amorphous Alloys | |
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Nanomaterials | |
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Polymers: Structure, General Properties, and Applications | |
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Introduction | |
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The Structure of Polymers | |
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Thermoplastics | |
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Thermosetting Plastics | |
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Additives in Plastics | |
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General Properties and Applications of Thermoplastics | |
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General Properties and Applications of Thermosetting Plastics | |
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Biodegradable Plastics | |
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Elastomers (Rubbers) | |
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Ceramics, Graphite, and Diamond: Structure, General Properties, and Applications | |
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Introduction | |
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The Structure of Ceramics | |
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General Properties and Applications of Ceramics | |
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Glasses | |
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Glass Ceramics | |
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Graphite | |
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Diamond | |
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Composite Materials: Structure, General Properties, and Applications | |
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Introduction | |
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The Structure of Reinforced Plastics | |
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Properties of Reinforced Plastics | |
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Applications of Reinforced Plastics | |
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Metal-Matrix Composites | |
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Ceramic-Matrix Composites | |
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Other Composites | |
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Metal-Casting Processes and Equipment | |
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Fundamentals of Metal Casting | |
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Introduction | |
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Solidification of Metals | |
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Fluid Flow | |
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Fluidity of Molten Metal | |
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Heat Transfer | |
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Defects | |
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Metal-Casting Processes | |
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Introduction | |
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Sand Casting | |
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Shell-Mold Casting | |
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Expendable-Pattern Casting (Lost Foam) | |
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Plaster-Mold Casting | |
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Ceramic-Mold Casting | |
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Investment Casting | |
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Vacuum Casting | |
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Permanent-Mold Casting | |
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Slush Casting | |
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Pressure Casting | |
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Die Casting | |
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Centrifugal Casting | |
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Squeeze Casting and Semisolid-Metal Forming | |
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Casting Techniques for Single-Crystal Components | |
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Rapid Solidifcation (Amorphous Alloys) | |
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Inspection of Castings | |
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Melting Practice and Furnaces | |
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Foundries and Foundry Automation | |
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Metal Casting: Design, Materials, and Economics | |
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Introduction | |
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Design Considerations | |
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Casting Alloys | |
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The Economics of Casting | |
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Forming and Shaping Processes and Equipment | |
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Rolling of Metals | |
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Introduction | |
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Flat Rolling | |
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Flat-Rolling Practice | |
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Rolling Mills | |
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Shape-Rolling Operations | |
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Production of Seamless Tubing and Pipe | |
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Continuous Casting and Rolling; Integrated Mills and Minimills | |
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Forging of Metals | |
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Introduction | |
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Open-Die Forging | |
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Impression-Die and Closed-Die Forging | |
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Related Forging Operations | |
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Rotary Swaging | |
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Forging-Die Design | |
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Die Materials and Lubrication | |
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Forgeability | |
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Forging Machines | |
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Forging Practice and Process Capabilities | |
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Die Manufacturing Methods | |
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Die Failures | |
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The Economics of Forging | |
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Extrusion and Drawing of Metals | |
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Introduction | |
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The Extrusion Process | |
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Extrusion Practice | |
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Hot Extrusion | |
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Cold Extrusion | |
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Impact Extrusion | |
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Hydrostatic Extrusion | |
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Extrusion Defects | |
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Extrusion Equipment | |
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The Drawing Process | |
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Drawing Practice | |
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Defects and Residual Stresses | |
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Drawing Equipment | |
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Sheet-Metal Forming Processes | |
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Introduction | |
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Shearing | |
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Sheet-Metal Characteristics | |
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Test Methods for Formability of Sheet Metals | |
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Bending Sheet and Plate | |
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Common Bending Operations | |
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Tube Bending and Forming | |
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Stretch Forming | |
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Deep Drawing | |
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Rubber Forming | |
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Spinning | |
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Superplastic Forming | |
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Explosive, Magnetic-Pulse, Peen, and Other Forming Processes | |
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The Manufacturing of Honeycomb Structures | |
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The Dent Resistance of Sheet-Metal Parts | |
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Equipment for Sheet-Metal Forming | |
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The Economics of Sheet-Metal Forming Processes | |
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Processing of Powder Metals, Ceramics, Glass, and Superconductors | |
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Introduction | |
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Production of Metal Powders | |
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Compaction of Metal Powders | |
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Sintering | |
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Secondary and Finishing Operations | |
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Design Considerations for Powder Metallurgy | |
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Process Capabilities | |
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Economics of Powder Metallurgy | |
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Shaping Ceramics | |
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Forming and Shaping of Glass | |
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Techniques for Strengthening and Treating Glass | |
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Design Considerations for Ceramics and Glasses | |
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Processing of Superconductors | |
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Forming and Shaping Plastics and Composite Materials | |
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Introduction | |
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Extrusion | |
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Injection Molding | |
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Blow Molding | |
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Rotational Molding | |
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Thermoforming | |
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Compression Molding | |
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Transfer Molding | |
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Casting | |
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Cold Forming and Solid-Phase Forming | |
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Processing Elastomers | |
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Processing Reinforced Plastics | |
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Processing Metal-Matrix Composites | |
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Processing Ceramic-Matrix Composites | |
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Design Considerations and Economics of Forming and Shaping Plastics | |
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Rapid Prototyping Operations | |
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Introduction | |
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Subtractive Processes | |
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Additive Processes | |
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Virtual Prototyping | |
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Applications | |
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Material-Removal Processes and Machines | |
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Fundamentals of Cutting | |
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Introduction | |
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The Mechanics of Chip Formation | |
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The Types of Chips Produced in Metal-Cutting | |
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The Mechanics of Oblique Cutting | |
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Cutting Forces and Power | |
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Temperatures in Cutting | |
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Tool Life: Wear and Failure | |
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Surface Finish and Integrity | |
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Machinability | |
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Cutting-Tool Materials and Cutting Fluids | |
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Introduction | |
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Carbon and Medium-Alloy Steels | |
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High-Speed Steels | |
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Cast-Cobalt Alloys | |
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Carbides | |
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Coated Tools | |
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Alumina-Based Ceramics | |
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Cubic Boron Nitride | |
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Silicon-Nitride Based Ceramics | |
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Diamond | |
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Whisker-Reinforced Tool Materials | |
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Cutting-Tool Reconditioning | |
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Cutting Fluids | |
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Machining Processes Used to Produce Round Shapes | |
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Introduction | |
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Turning Parameters | |
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Lathes and Lathe Operations | |
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High-Speed Machining, Ultraprecision Machining, and Hard Turning | |
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Cutting Screw Threads | |
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Boring and Boring Machines | |
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Drilling and Drills | |
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Drilling Machines | |
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Reaming and Reamers | |
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Tapping and Taps | |
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Design Considerations for Drilling, Reaming and Tapping | |
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Machining Processes used to Produce Various Shapes | |
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Introduction | |
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Milling Operations | |
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Milling Machines | |
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Planing and Shaping | |
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Broaching and Broaching Machines | |
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Sawing | |
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Filing and Finishing | |
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Gear Manufacturing by Machining | |
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Machining and Turning Centers, Machine-Tool Structures, and Machining Economics | |
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Introduction | |
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Machining and Turning Centers | |
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Machine-Tool Structures | |
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Vibration and Chatter in Machining | |
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Machining Economics | |
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Abrasive Machining and Finishing Operations | |
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Introduction | |
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Abrasives | |
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Bonded Abrasives (Grinding Wheels) | |
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The Grinding Process | |
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Grinding Wheel Wear | |
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Grinding Operations and Machines | |
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Grinding Fluids | |
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Design Considerations for Grinding | |
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Ultrasonic Machining | |
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Finishing Operations | |
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Deburring | |
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Economics of Grinding and Finishing Operations | |
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Advanced Machining Processes and Nanofabrication | |
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Introduction | |
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Chemical Machining | |
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Electrochemical Machining | |
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Electrochemical Grinding | |
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Electrical-Discharge Machining | |
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Wire EDM | |
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Laser-Beam Machining | |
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Electron-Beam Machining and Plasma-Arc Cutting | |
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Water-Jet Machining | |
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Abrasive-Jet Machining | |
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Nanofabrication | |
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Micromachining | |
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The Economics of Advanced Machining Processes | |
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Joining Processes and Equipment | |
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Fusion Welding Processes | |
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Introduction | |
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Oxyfuel Gas Welding | |
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Arc-Welding Processes: Consumable Electrode | |
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Electrodes | |
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Arc-Welding Processes: Nonconsumable Electrode | |
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Thermit Welding | |
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Electron-Beam Welding | |
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Laser-Beam Welding | |
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Cutting | |
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Welding Safety | |
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Solid-State Welding Processes | |
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Introduction | |
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Cold Welding | |
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Ultrasonic Welding | |
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Friction Welding | |
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Resistance Welding | |
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Explosion Welding | |
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Diffusion Bonding (Welding) | |
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Diffusion Bonding/Superplastic Forming | |
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The Metallurgy of Welding: Welding Design and Process Selection | |
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Introduction | |
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The Welded Joint | |
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Weld Quality | |
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Weldability | |
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Testing Welded Joints | |
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Weld Design and Process Selection | |
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Brazing, Soldering, Adhesive Bonding, and Mechanical Fastening Processes | |
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Introduction | |
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Brazing | |
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Soldering | |
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Adhesive Bonding | |
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Mechanical Fastening | |
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Joining Plastics | |
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Surface Technology | |
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Surfaces: Their Nature, Roughness, and Measurement | |
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Introduction | |
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Surface Structure and Properties | |
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Surface Integrity | |
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Surface Texture | |
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Surface Roughness | |
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Tribology: Friction, Wear, and Lubrication | |
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Introduction | |
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Friction in Metals | |
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Friction in Plastics and Ceramics | |
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Reducing Friction | |
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Friction Measurement | |
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Wear | |
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Wear of Plastics and Ceramics | |
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Wear Measurement | |
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Lubrication | |
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Metalworking Fluids | |
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Solid Lubricants | |
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Conversion Coatings | |
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Lubricant Selection | |
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Surface Treatment, Coating and Cleaning | |
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Introduction | |
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Mechanical Surface Treatment and Coating | |
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Case Hardening and Hard Facing | |
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Thermal Spraying | |
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Vapor Deposition | |
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Ion Implantation | |
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Diffusion Coating | |
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Electroplating, Electroless Plating, and Electroforming | |
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Anodizing | |
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Conversion Coating | |
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Hot Dipping | |
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Porcelain Enameling, Ceramic Coating, and Organic Coatings | |
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Diamond Coating | |
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Painting | |
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Surface Texturing | |
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Cleaning Surfaces | |
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Fabrication of Microelectronic Devices | |
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Introduction | |
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Semiconductors and Silicon | |
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Crystal Growing and Wafer Preparation | |
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Film Deposition | |
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Oxidation | |
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Lithography | |
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Etching | |
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Diffusion and Ion Implantation | |
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Metallization and Testing | |
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Bonding and Packaging | |
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Yield and Reliability | |
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Printed Circuit Boards | |
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Common Aspects of Manufacturing | |
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Engineering Metrology and Instrumentation | |
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Introduction | |
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Measurement Standards | |
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Line-Graduated Instruments | |
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Comparative Length-Measuring Instruments | |
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Measuring Straightness, Flatness, Roundness, and Profile | |
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Coordinate Measuring and Layout Machines | |
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Gages | |
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Optical Instruments | |
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Automated Measurements | |
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General Characteristics and Selection of Measuring Instruments | |
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Geometric Dimensioning and Tolerancing | |
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Quality Assurance, Testing, and Inspection | |
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Introduction | |
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Product Quality | |
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Quality Assurance | |
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Total Quality Management | |
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Taguchi Methods | |
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The ISO and QS Standards | |
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Statistical Methods of Quality Control | |
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Statistical Process Control | |
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Reliability | |
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Nondestructive Testing | |
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Destructive Testing | |
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Automated Inspection | |
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Human Factors Engineering, Safety, and Product Liability | |
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Introduction | |
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Human-Factors Engineering | |
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Safety | |
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Environmental Considerations | |
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Product Liability | |
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Examples of Product Liability Claims | |
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Manufacturing in a Competitive Environment | |
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Automation of Manufacturing Processes | |
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Introduction | |
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Automation | |
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Numerical Control | |
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Programming for Numerical Control | |
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Adaptive Control | |
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Material Handling and Movement | |
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Industrial Robots | |
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Sensor Technology | |
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Flexible Fixturing | |
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Design for Assembly, Disassembly, and Service | |
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Computer-Integrated Manufacturing Systems | |
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Introduction | |
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Manufacturing Systems | |
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Computer-Integrated Manufacturing | |
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Computer-Aided Design and Engineering | |
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Computer-Aided Manufacturing | |
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Computer-Aided Process Planning | |
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Computer Simulation of Manufacturing Processes and Systems | |
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Group Technology | |
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Cellular Manufacturing | |
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Flexible Manufacturing Systems | |
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Just-in-Time Production | |
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Communications Networks in Manufacturing | |
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Artificial Intelligence | |
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The Factory of the Future | |
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Competitive Aspects of Manufacturing | |
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Introduction | |
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Selection of Materials | |
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Product Design and Quantity of Material | |
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Substitution of Materials | |
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Selection of Manufacturing Processes | |
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Process Capabilities | |
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Manufacturing Costs | |
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Value Engineering | |
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Index | |