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Preface | |
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Introduction to DeGarmo's Materials and Processes in Manufacturing | |
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Materials, Manufacturing, and the Standard of Living | |
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Manufacturing and Production Systems | |
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Case Study: Famous Manufacturing Engineers | |
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Properties of Materials | |
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Introduction | |
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Static Properties | |
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Dynamic Properties | |
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Temperature Effects (Both High and Low) | |
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Machinability, Formability, and Weldability | |
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Fracture Toughness and the Fracture Mechanics Approach | |
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Physical Properties | |
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Testing Standards and Concerns | |
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Case Study: Separation of Mixed Materials | |
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Nature of Metals and Alloys | |
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Structure-Property-Processing-Performance Relationships | |
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The Structure of Atoms | |
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Atomic Bonding | |
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Secondary Bonds | |
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Atom Arrangements in Materials | |
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Crystal Structures of Metals | |
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Development of a Grain Structure | |
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Elastic Deformation | |
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Plastic Deformation | |
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Dislocation Theory of Slippage | |
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Strain Hardening or Work Hardening | |
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Plastic Deformation in Polycrystalline Metals | |
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Grain Shape and Anisotropic Properties | |
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Fracture of Metals | |
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Cold Working, Recrystallization, and Hot Working | |
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Grain Growth | |
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Alloys and Alloy Types | |
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Atomic Structure and Electrical Properties | |
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Equilibrium Phase Diagrams and the Iron-Carbon System | |
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Introduction | |
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Phases | |
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Equilibrium Phase Diagrams | |
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Iron-Carbon Equilibrium Diagram | |
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Steels and the Simplified Iron-Carbon Diagram | |
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Cast Irons | |
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Case Study: The Blacksmith Anvils | |
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Heat Treatment | |
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Introduction | |
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Processing Heat Treatments | |
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Heat Treatments Used to Increase Strength | |
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Strengthening Heat Treatments for Nonferrous Metals | |
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Strengthening Heat Treatments for Steel | |
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Surface Hardening of Steel | |
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Furnaces | |
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Heat Treatment and Energy | |
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Case Study: A Carpenter's Claw Hammer | |
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Ferrous Metals and Alloys | |
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Introduction to History-Dependent Materials | |
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Ferrous Metals | |
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Iron | |
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Steel | |
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Stainless Steels | |
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Tool Steels | |
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Alloy Cast Steels and Irons | |
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Case Study: Interior Tub of a Top-Loading Washing Machine | |
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Nonferrous Metals and Alloys | |
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Introduction | |
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Copper and Copper Alloys | |
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Aluminum and Aluminum Alloys | |
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Magnesium and Magnesium Alloys | |
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Zinc-Based Alloys | |
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Titanium and Titanium Alloys | |
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Nickel-Based Alloys | |
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Superalloys and Other Metals Designed for High-Temperature Service | |
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Lead and Tin, and Their Alloys | |
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Some Lesser Known Metals and Alloys | |
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Metallic Glasses | |
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Graphite | |
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Case Study: Nonsparking Wrench | |
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Nonmetallic Materials: Plastics, Elastomers, Ceramics, and Composites | |
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Introduction | |
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Plastics | |
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Elastomers | |
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Ceramics | |
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Composite Materials | |
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Case Study: Two-Wheel Dolly Handles | |
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Material Selection | |
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Introduction | |
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Material Selection and Manufacturing Processes | |
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The Design Process | |
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Procedures for Material Selection | |
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Additional Factors to Consider | |
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Consideration of the Manufacturing Process | |
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Ultimate Objective | |
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Materials Substitution | |
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Effect of Product Liability on Materials Selection | |
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Aids to Material Selection | |
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Case Study: Material Selection | |
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Measurement and Inspection and Testing | |
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Introduction | |
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Standards of Measurement | |
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Allowance and Tolerance | |
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Inspection Methods for Measurement | |
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Measuring Instruments | |
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Vision Systems for Measurement | |
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Coordinate Measuring Machines | |
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Angle-Measuring Instruments | |
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Gages for Attributes Measuring | |
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Testing | |
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Visual Inspection | |
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Liquid Penetrant Inspection | |
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Magnetic Particle Inspection | |
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Ultrasonic Inspection | |
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Radiography | |
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Eddy-Current Testing | |
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Acoustic Emission Monitoring | |
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Other Methods of Nondestructive Testing and Inspection | |
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Dormant versus Critical Flaws | |
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Case Study: Measuring An Angle | |
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Fundamentals of Casting | |
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Introduction to Materials Processing | |
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Introduction to Casting | |
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Casting Terminology | |
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The Solidification Process | |
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Patterns | |
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Design Considerations in Castings | |
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The Casting Industry | |
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Case Study: The Cast Oil-Field Fitting | |
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Expendable-Mold Casting Processes | |
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Introduction | |
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Sand Casting | |
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Cores and Core Making | |
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Other Expendable-Mold Processes with Multiple-Use Patterns | |
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Expendable-Mold Processes Using Single-Use Patterns | |
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Shakeout, Cleaning, and Finishing | |
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Summary | |
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Case Study: Movable and Fixed Jaw Pieces for a Heavy-Duty Bench Vise | |
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Multiple-Use-Mold Casting Processes | |
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Introduction | |
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Permanent-Mold Casting | |
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Die Casting | |
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Squeeze Casting and Semisolid Casting | |
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Centrifugal Casting | |
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Continuous Casting | |
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Melting | |
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Pouring Practice | |
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Cleaning, Finishing, and Heat Treating of Castings | |
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Automation in Foundry Operations | |
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Process Selection | |
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Case Study: Baseplate for a Household Steam Iron | |
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Fabrication of Plastics, Ceramics, and Composites | |
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Introduction | |
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Fabrication of Plastics | |
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Processing of Rubber and Elastomers | |
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Processing of Ceramics | |
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Fabrication of Composite Materials | |
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Case Study: Fabrication of Lavatory Wash Basins | |
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Fundamentals of Metal Forming | |
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Introduction | |
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Forming Processes: Independent Variables | |
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Dependent Variables | |
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Independent-Dependent Relationships | |
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Process Modeling | |
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General Parameters | |
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Friction and Lubrication under Metalworking Conditions | |
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Temperature Concerns | |
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Case Study: Repairs to a Damaged Propeller | |
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Bulk Forming Processes | |
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Introduction | |
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Classification of Deformation Processes | |
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Bulk Deformation Processes | |
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Rolling | |
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Forging | |
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Extrusion | |
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Wire, Rod, and Tube Drawing | |
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Cold Forming, Cold Forging, and Impact Extrusion | |
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Piercing | |
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Other Squeezing Processes | |
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Surface Improvement by Deformation Processing | |
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Case Study: Handle and Body of a Large Ratchet Wrench | |
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Sheet-Forming Processes | |
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Introduction | |
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Shearing Operations | |
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Bending | |
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Drawing and Stretching Processes | |
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Alternative Methods of Producing Sheet-Type Products | |
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Pipe Welding | |
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Presses | |
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Case Study: Fabrication of a One-Piece Brass Flashlight Case | |
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Powder Metallurgy | |
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Introduction | |
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The Basic Process | |
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Powder Manufacture | |
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Rapidly Solidified Powder (Microcrystalline and Amorphous) | |
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Powder Testing and Evaluation | |
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Powder Mixing and Blending | |
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Compacting | |
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Sintering | |
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Hot-Isostatic Pressing | |
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Other Techniques to Produce High-Density P/M Products | |
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Metal Injection Molding (MIM) or Powder Injection Molding (PIM) | |
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Secondary Operations | |
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Properties of P/M Products | |
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Design of Powder Metallurgy Parts | |
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Powder Metallurgy Products | |
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Advantages and Disadvantages of Powder Metallurgy | |
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Process Summary | |
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Case Study: Impeller for an Automobile Water Pump | |
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Electronic Electrochemical Chemical and Thermal Machining Processes | |
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Introduction | |
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Chemical Machining Processes | |
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Electrochemical Machining Processes | |
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Electrical Discharge Machining | |
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Case Study: Fire Extinguisher Pressure Gage | |
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Fundamentals of Machining/Orthogonal Machining | |
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Introduction | |
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Fundamentals | |
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Energy and Power in Machining | |
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Orthogonal Machining (Two Forces) | |
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Merchant's Model | |
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Mechanics of Machining (Statics) | |
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Shear Strain [Gamma] and Shear Front Angle [phi] | |
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Mechanics of Machining (Dynamics) | |
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Summary | |
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Case Study: Orthogonal Plate Machining Experiment at Auburn University | |
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Cutting Tools for Machining | |
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Introduction | |
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Cutting-Tool Materials | |
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Tool Geometry | |
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Tool Coating Processes | |
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Tool Failure and Tool Life | |
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Flank Wear | |
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Economics of Machining | |
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Cutting Fluids | |
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Case Study: Comparing Tool Materials Based on Tool Life | |
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Turning and Boring Processes | |
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Introduction | |
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Fundamentals of Turning, Boring, and Facing Turning | |
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Lathe Design and Terminology | |
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Cutting Tools for Lathes | |
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Workholding in Lathes | |
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Case Study: Estimating the Machining Time for Turning | |
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Drilling and Related Hole-Making Processes | |
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Introduction | |
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Fundamentals of the Drilling Process | |
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Types of Drills | |
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Tool Holders for Drills | |
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Workholding for Drilling | |
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Machine Tools for Drilling | |
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Cutting Fluids for Drilling | |
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Counterboring, Countersinking, and Spot Facing | |
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Reaming | |
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Case Study: Bolt-down Leg on a Casting | |
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Milling | |
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Introduction | |
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Fundamentals of Milling Processes | |
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Milling Tools and Cutters | |
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Machines for Milling | |
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Case Study: HSS versus Tungsten Carbide Milling | |
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Workholding Devices for Machine Tools | |
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Introduction | |
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Conventional Fixture Design | |
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Design Steps | |
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Clamping Considerations | |
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Chip Disposal | |
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Unloading and Loading Time | |
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Example of Jig Design | |
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Types of Jigs | |
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Conventional Fixtures | |
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Modular Fixturing | |
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Setup and Changeover | |
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Clamps | |
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Other Workholding Devices | |
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Economic Justification of Jigs and Fixtures | |
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Case Study: Fixture versus No Fixture in Milling | |
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Numerical Control (NC) and the A(4) Level of Automation | |
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Introduction | |
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Basic Principles of Numerical Control | |
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Machining Center Features and Trends | |
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Ultra-High-Speed Machining Centers (UHSMCs) | |
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Summary | |
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Case Study: Process Planning for the MfE | |
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Other Machining Processes | |
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Introduction | |
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Introduction to Shaping and Planing | |
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Introduction to Broaching | |
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Fundamentals of Broaching | |
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Broaching Machines | |
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Introduction to Sawing | |
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Introduction to Filing | |
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Case Study: Cost Estimating-Planing vs. Milling | |
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Abrasive Machining Processes | |
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Introduction | |
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Abrasives | |
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Grinding Wheel Structure and Grade | |
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Grinding Wheel Identification | |
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Grinding Machines | |
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Honing | |
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Superfinishing | |
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Free Abrasives | |
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Case Study: Overhead Crane Installation | |
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Thread and Gear Manufacturing | |
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Introduction | |
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Thread Making | |
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Internal Thread Cutting-Tapping | |
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Thread Milling | |
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Thread Grinding | |
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Thread Rolling | |
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Gear Making | |
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Gear Types | |
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Gear Manufacturing | |
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Machining of Gears | |
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Gear Finishing | |
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Gear Inspection | |
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Case Study: Bevel Gear for a Riding Lawn Mower | |
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Fundamentals of Joining | |
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Introduction to Consolidation Processes | |
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Classification of Welding and Thermal Cutting Processes | |
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Some Common Concerns | |
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Types of Fusion Welds and Types of Joints | |
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Design Considerations | |
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Heat Effects | |
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Weldability or Joinability | |
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Summary | |
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Gas Flame and Arc Processes | |
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Oxyfuel-Gas Welding | |
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Oxygen Torch Cutting | |
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Flame Straightening | |
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Arc Welding | |
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Consumable-Electrode Arc Welding | |
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Nonconsumable-Electrode Arc Welding | |
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Welding Equipment | |
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Arc Cutting | |
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Metallurgical and Heat Effects in Thermal Cutting | |
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Case Study: Bicycle Frame Construction and Repair | |
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Resistance and Solid-State Welding Processes | |
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Introduction | |
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Theory of Resistance Welding | |
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Resistance Welding Processes | |
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Advantages and Limitations of Resistance Welding | |
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Solid-State Welding Processes | |
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Case Study: Field Repair to a Power Transformer | |
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Other Welding Processes, Brazing and Soldering | |
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Introduction | |
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Other Welding and Cutting Processes | |
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Surface Modification by Welding-Related Processes | |
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Brazing | |
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Soldering | |
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Adhesive Bonding, Mechanical Fastening, and Joining of Nonmetals | |
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Adhesive Bonding | |
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Mechanical Fastening | |
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Joining of Plastics | |
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Joining of Ceramics and Glass | |
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Joining of Composites | |
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Case Study: Golf Club Heads with Insert | |
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Surface Engineering | |
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Introduction | |
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Mechanical Cleaning and Finishing Blast Cleaning | |
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Chemical Cleaning | |
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Coatings | |
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Vaporized Metal Coatings | |
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Clad Materials | |
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Textured Surfaces | |
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Coil-Coated Sheets | |
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Edge Finishing and Burrs | |
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Surface Integrity | |
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Case Study: Dana Lynn's Fatigue Lesson | |
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Quality Engineering | |
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Introduction | |
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Determining Process Capability | |
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Inspection to Control Quality | |
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Process Capability Determination from Control Chart Data | |
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Determining Causes for Problems in Quality | |
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Summary | |
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Case Study: Boring QC Chart Blunders | |
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Manufacturing Automation (web-based chapter) (www.wiley.com/college/DeGarmo) | |
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The Enterprise (web-based chapter) (www.wiley.com/college/DeGarmo) | |
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Rapid Prototyping, Tooling And Fabrication (web-based chapter) (www.wiley.com/college/DeGarmo) | |
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Selected References for Additional Study (web-based) | |
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Index | |