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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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| Manufacturing Systems Design | |
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| Introduction | |
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| Manufacturing Systems | |
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| Control of the Manufacturing System | |
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| Classification of Manufacturing Systems | |
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| Summary of Factory Designs | |
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| Case Study Jury Duty for an Engineer | |
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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 Testing 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 Fish Hooks | |
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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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| Cast Irons | |
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| Cast Steels | |
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| The Role of Processing on Cast Properties | |
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| Case Study The Paper Clip | |
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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 and Zinc Alloys | |
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| Titanium and Titanium Alloys | |
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| Nickel-Based Alloys | |
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| Superalloys, Refractory Metals, and Other Materials 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 Hip Replacement Prosthetics | |
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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 Lightweight Armor | |
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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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| Approaches to 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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| 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 Automotive and Light Truck Fuel Tanks | |
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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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| Formability | |
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| Case Study Interior Tub of a Top-Loading Washing Machine | |
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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 Manufacture | |
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| Presses | |
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| Case Study Automotive Body Panels | |
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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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| Microcrystalline and Amorphous Material Produced by Rapid Cooling | |
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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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| Recent Advances in Sintering | |
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| Hot-Isostatic Pressing | |
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| Other Techniques to Produce High-Density Powder Metallurgy Products | |
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| Metal Injection Molding or Powder Injection Molding | |
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| Secondary Operations | |
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| Properties of Powder Metallurgy 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 Steering Gear for a Riding Lawn Mower/Garden Tractor | |
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| Additive Processes: Rapid Prototyping and Direct-Digital Manufacturing | |
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| Introduction | |
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| Rapid Prototyping and Direct-Digital Manufacturing | |
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| Layerwise Manufacturing | |
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| Liquid-Based Processes | |
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| Powder-Based Processes | |
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| Deposition-Based Processes | |
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| Uses and Applications | |
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| Pros, Cons, and Current and Future Trends | |
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| Economic Considerations | |
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| Fundamentals of Machining/Orthogonal Machining | |
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| Introduction | |
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| Fundamentals | |
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| Forces and Power in Machining | |
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| Orthogonal Machining (Two Forces) | |
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| Chip Thickness Ratio | |
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| Mechanics of Machining (Statics) | |
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| Shear Strain, g, and Shear Front Angle | |
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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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| Cutting Fluids | |
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| Economics of Machining | |
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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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| Sawing, Broaching, and Other Machining Processes | |
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| Introduction | |
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| Introduction to Sawing | |
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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 Shaping and Planing | |
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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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| Design Considerations In Grinding | |
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| Case Study Process Planning for the MfE | |
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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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| Tool 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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| Nontraditional Manufacturing 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 Vented Cap Screws | |
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| Lean Engineering | |
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| Introduction | |
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| The Lean Engineer | |
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| The Lean Production System | |
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| Linked-Cell Manufacturing System Design Rules | |
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| Manufacturing System Designs | |
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| Preliminary Steps to Lean Production | |
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| Methodology for Implementation of Lean Production | |
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| Design Rule MT < CT | |
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| Decouplers | |
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| Integrating Production Control | |
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| Integrating Inventory Control | |
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| Lean Manufacturing Cell Design | |
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| Machine Tool Design for Lean Manufacturing Cells | |
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| L-CMS Strategy | |
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| Case Study Cycle Time for a Manufacturing Cell | |
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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 Manufacture of an Automobile Muffler | |
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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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| Case Study Impeller of a Pharmaceutical Company Industrial Shredder/Disposal | |
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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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| Measurement and Inspection | |
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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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| Case Study Measuring An Angle | |
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| Quality Engineering | |
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| Introduction | |
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| Determining Process Capability | |
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| Introduction to Statistical Quality Control | |
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| Sampling Errors | |
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| Gage Capability | |
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| Just in Time/Total Quality Control | |
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| Six Sigma | |
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| Summary | |
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| Case Study Boring QC Chart Blunders | |
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| Surface Engineering | |
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| Introduction | |
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| Abrasive Cleaning and Finishing | |
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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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| Case Study Dana Lynn's Fatigue Lesson | |
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| Micro/Meso/Nano Fabrication Processes | |
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| Introduction | |
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| Additive Processes | |
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| Metrology at the Micro/Meso/Nano Level | |
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| Manufacturing Automation | |
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| Introduction | |
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| The A(4) Level of Automation | |
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| A(5) Evaluation or Adaptive Control | |
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| A(6) Level of Automation and Beyond | |
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| Robotics | |
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| Computer-Integrated Manufacturing Automation | |
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| Computer-Aided Design | |
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| Computer-Aided Manufacturing | |
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| Summary | |
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| NC/CNC Processes and Adaptive Control: A(4) and A(5) Levels 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 | |
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| Summary | |
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| Microelectric Manufacturing and Assembly | |
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| Introduction | |
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| How Electronic Products Are Made | |
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| Semiconductors | |
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| How Integrated Circuits Are Made | |
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| How the Silicon Wafer Is Made | |
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| Fabricating Integrated Circuits on Silicon Wafers | |
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| Thin-Film Deposition | |
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| Integrated Circuit Packaging | |
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| Printed Circuit Boards | |
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| Electronic Assembly | |
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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 CuttingTapping | |
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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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| Nondestructive Inspection and Testing | |
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| Destructive versus Nondestructive Testing 1215 (web-based chapter) | |
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| Other Methods of Nondestructive Testing and Inspection | |
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| The Enterprise (Production Systems) 1230 (web-based chapter) | |
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| Introduction | |
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| Axiomatic Design of Systems | |
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| Enterprise System Design Principles | |
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| Functional Areas in the Production System | |
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| Human Resources (Personnel) Department | |
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| Index I-2 | |
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| Selected References for Additional Study S1 | |