| Manufacturing Foundations | |
| Manufacturing | p. 1 |
| Hand Tools to Machine Tools | p. 1 |
| Early Hand Tools | |
| The Iron Age | |
| Industrial Revolution | |
| Automation | |
| Types of Products | p. 5 |
| Organization for Manufacturing | p. 5 |
| Types of Manufacturing Systems | |
| Small Organizations | |
| Large Organizations | |
| Manufacturing Engineering | |
| Questions | p. 10 |
| The Competitive Challenge in Manufacturing | |
| Importance of Manufacturing as an Economic Activity | p. 13 |
| State of the Industry | p. 13 |
| Labor Productivity | p. 14 |
| International Competitiveness | p. 16 |
| Balance of Trade | |
| Trade Agreements | |
| Manufacturing Innovations | p. 18 |
| Machine Tools | |
| Manufacturing Systems | |
| Questions | p. 21 |
| Material Properties and Testing | |
| Metal Structures | p. 23 |
| Unit Cells | |
| Changes in Crystal Structure | |
| Crystalline Structure and Physical Properties | |
| Fracture | |
| Fundamentals of Metal Alloys | p. 27 |
| Metallic Solid Solutions and Compounds | |
| How Alloys Melt | |
| Equilibrium Diagrams | |
| Alloys in the Solid State | |
| Grain Growth | |
| Metallurgy of Iron and Steel | p. 33 |
| Iron and Iron Carbide Solid Solutions | |
| Pearlite | |
| Hypoeutectoid and Hypereutectoid Steels | |
| Martensite | |
| Other Structures of Steel | |
| Practical Aspects of Carbon in Steel | |
| Grain Size of Steel | |
| Solidification of Cast Iron | |
| Testing of Engineering Materials | p. 38 |
| Tension Test | |
| Hardness Testing | |
| Notched-bar Impact Testing | |
| Bend Tests | |
| High-temperature Tests | |
| Fatigue Testing | |
| Fracture Toughness Tests | |
| Nodestructive Testing | |
| Corrosion Testing | |
| Questions | p. 52 |
| Problems | p. 53 |
| Iron and Steel | |
| Iron, Steel, and Power | p. 57 |
| Iron Making | p. 57 |
| The Blast Furnace and its Chemistry | p. 59 |
| Steelmaking | p. 59 |
| The Basic Oxygen Process | |
| The Electric-furnace Process | |
| Finishing and Ingot Teeming | p. 64 |
| Special Techniques in Steel Refining | p. 65 |
| Aluminum | p. 65 |
| Copper | p. 66 |
| Miscellaneous Metals | p. 68 |
| Magnesium | |
| Zinc | |
| Lead | |
| Tin | |
| Titanium | |
| Tungsten | |
| Steel | p. 69 |
| Effects of Alloying Elements in Ferrous Alloys | p. 69 |
| Carbon Steels | p. 71 |
| Alloy Steels | p. 72 |
| Questions | p. 76 |
| Nonferrous Metals and Alloys | |
| Effects of Alloying on Properties | p. 79 |
| Aluminum | p. 80 |
| Aluminum Alloys | |
| Magnesium | p. 81 |
| Magnesium Alloys | |
| Copper | p. 83 |
| Copper Alloys | |
| Zinc | p. 84 |
| Zinc Alloys | |
| Tianium | p. 85 |
| Titanium Alloys | |
| Nickel and its Alloys | p. 86 |
| The White Metals | p. 86 |
| Refractory Metals | p. 86 |
| Precious Metals | p. 87 |
| Questions | p. 87 |
| Enhancing Material Properties | |
| Heat Treatment Principles | p. 89 |
| Heat Treatment of Nonallotropic Alloys | p. 90 |
| Heat Treatment Processes for Steels | p. 91 |
| Steel Hardening | |
| Annealing of Steel | |
| Surface-hardening of Steel | p. 99 |
| Induction-hardening | |
| Flame-hardening | |
| Comparison of Methods | |
| Carburizing to Case-harden | |
| Cyaniding | |
| Nitriding | |
| Laser Beam Hardening | |
| Electron Beam Hardening | |
| Heat Treatment of Nonferrous Metals | p. 103 |
| Heat-treating Furnaces | p. 103 |
| Hearth Furnaces | |
| Rotary Furnaces | |
| Continuous Furnaces | |
| Furnace Atmospheres | |
| Molten Baths for Heat Treating | |
| Bath Furnaces | |
| Design Considerations for Heat Treatment | p. 109 |
| Cost Considerations | p. 109 |
| Process Automation | p. 109 |
| Questions | p. 109 |
| Nonmetallic Materials | |
| Nonmetallic Material Families | p. 111 |
| Plastic Materials | p. 112 |
| Resins and Polymers | |
| Additives | |
| Plastic Products | |
| Thermosetting Plastics | |
| Thermoplastics | |
| Elastomers (Rubbers) | |
| Silicones | |
| Adhesives | |
| Plastics Processing | p. 126 |
| Compression Molding | |
| Transfer Molding | |
| Injection Molding | |
| Casting | |
| Extrusion and Pultrusion | |
| Foams | |
| Laminates and Reinforced Plastic Molding | |
| Forming Plastic Sheets | |
| Shell Molding | |
| Joining Plastics | |
| Machining Plastics | |
| Rubber Processing | |
| Design of Molded Plastic Parts | p. 135 |
| Ceramics | p. 136 |
| Structure | |
| Clay Products | |
| Refractory Materials | |
| Glass | |
| Cermets | |
| Mechanical and Electrical Applications | |
| Ceramic Cutting Tools | |
| Questions | p. 138 |
| Problems | p. 139 |
| Metal Casting Expendable Molds | |
| Sand Casting Principles | p. 141 |
| The Behavior of Cast Metal | |
| The Mold and Its Components | |
| Making Molds | p. 146 |
| Hand Tools for Molding | |
| Mold-making Steps | |
| Molding Machines | |
| Cores | p. 149 |
| Core Making | |
| Patterns | p. 153 |
| Types | |
| Material | |
| Layout | |
| Shrinkage Allowance | |
| Other Allowances | |
| Draft | |
| Fillets | |
| Locating Pads | |
| Color Coding | |
| Sands and Other Mold Ingredients | p. 156 |
| Molding Sand | |
| Core Sand | |
| Melting Metals in the Foundry | p. 161 |
| The Cupola | |
| Melting of Nonferrous Metals | |
| Pouring and Cleaning Castings | p. 168 |
| Pouring Methods | |
| Cleaning Castings | |
| Shell Mold Casting | p. 169 |
| Advantages | |
| Metallurgy of Castings | p. 171 |
| Cast Iron | |
| Nonferrous Cast Alloys | |
| Design of Castings | p. 173 |
| Draft | |
| Tolerances | |
| Questions | p. 174 |
| Problems | p. 181 |
| Metal Casting Reusable Molds | |
| Metal Mold Casting Processes | p. 183 |
| Permanent Mold Casting | |
| Low-pressure Casting | |
| Slush Casting | |
| Die Casting | |
| Die-casting Dies | |
| Die-casting Machines | |
| Finishing Die Castings | |
| Centrifugal Casting | |
| Comparison of Metal Mold-casting Methods | |
| Designing Castings for Metal Molds | |
| Plaster Mold Casting | p. 191 |
| Precision Investment Casting | p. 193 |
| Advantages and Limitations | |
| Continuous Casting | p. 195 |
| Applications | |
| Advantages and Limitations | |
| Questions | p. 196 |
| Problems | p. 196 |
| Powder Metallurgy | |
| Introduction | p. 199 |
| Basic Powder Metallurgy Process | p. 199 |
| Metal Powder Production and Blending | p. 200 |
| Fabrication Processes | p. 201 |
| Pressing or Compaction | |
| Sintering | |
| Finishing Operations | p. 206 |
| Metal Composites | p. 207 |
| Design of Powder Metal Parts | p. 207 |
| Process Automation | p. 207 |
| Questions | p. 208 |
| Problems | p. 209 |
| Hot and Cold Working of Metals | |
| Wrought Metals | p. 211 |
| Hot Working | p. 211 |
| Cold Working | p. 212 |
| Warm Working | p. 214 |
| Rolling | p. 214 |
| Principles | |
| Rolling Mills | |
| Hot-rolling Steels | |
| Cold Rolling | |
| Quality and Cost | |
| Cold Drawing | p. 219 |
| Process | |
| Manufacture of Pipe and Tubing | p. 220 |
| Butt-welded Pipe | |
| Lap-welded Pipe | |
| Seamless Tubing | |
| Forging | p. 223 |
| Heating the Work | |
| Hammer Forging | |
| Drop Forging | |
| Drop Hammers | |
| Press Forging | |
| High-energy-rate Forging | |
| Upset Forging | |
| Forging with Rolls | |
| Quality and Cost | |
| Extrusion | p. 233 |
| Principles | |
| Hot Extrusion | |
| Cold Extrusion | |
| Questions | p. 237 |
| Problems | p. 239 |
| Metal Shearing and Forming | |
| Introduction | p. 243 |
| Metal Shearing Operations | p. 243 |
| Types | |
| Principles | |
| Bending | p. 247 |
| Punch and Die Bending | |
| Tube and Structural Shape Bending | |
| Cold-roll Forming | |
| Drawing and Stretching | p. 252 |
| Rigid Die Drawing | |
| Flexible Die Drawing and Forming | |
| Hydrostatic Forming | |
| Metal Spinning | |
| Roll Turning | |
| Stretching and Shrinking | |
| High-energy-rate Forming | |
| Ultrasonic Aid to Forming | |
| Squeezing | p. 263 |
| Cold Heading | |
| Swaging | |
| Sizing, Coining, and Hobbing | |
| Ironing | |
| Riveting, Staking, and Stitching | |
| Presses | p. 266 |
| Frame and Bed | |
| Press Ram | |
| Press Drives | |
| Hydraulic Presses | |
| Power Transmission | |
| Applications | |
| Specialized Presses | |
| Press Brakes and Shears | |
| Hole-punching Machines | |
| High-production Presses | |
| Press Tools and Accessories | p. 279 |
| Dies | |
| Stock-feeding Devices | |
| Safety Devices | |
| Questions | p. 285 |
| Problems | p. 287 |
| Welding Processes | |
| Introduction | p. 291 |
| Common Welding Process Classifications | p. 291 |
| Electric-arc Welding | p. 291 |
| Parameters | |
| Applications | |
| Electrodes | |
| Manual Arc Welding | |
| Automatic Arc Welding | |
| Sources of Current | |
| Gas-shielded Arc Welding | |
| Plasma-arc Welding | |
| Submerged-arc Welding | |
| Vertical Welding | |
| Stud Welding | |
| Energy-ray Welding | p. 302 |
| Electron-beam Welding | |
| Laser Welding | |
| Resistance Welding | p. 306 |
| Fundamentals | |
| Equipment | |
| Spot Welding | |
| Projection Welding | |
| Seam Welding | |
| Upset-butt Welding | |
| Flash-butt Welding | |
| Percussion Welding | |
| Thermit Welding | p. 314 |
| Principles | |
| Procedures | |
| Applications | |
| Gas Welding | p. 316 |
| Fuel Gases | |
| Oxyacetylene Gas Welding | |
| Solid-state Welding | p. 318 |
| Friction Welding | |
| Ultrasonic Welding | |
| Explosion Welding | |
| Diffusion Bonding | |
| Welding Fundamentals | p. 320 |
| Welded Joints and Welding Symbols | |
| Metallurgy of Welding | |
| Control of Weld Quality | |
| Cost Comparisons | p. 326 |
| Welding Costs | |
| Comparison of Welding and Casting | |
| Comparison of Welding and Riveting | |
| Comparison of Arc-Welding Processes | |
| Process Automation | p. 330 |
| Questions | p. 330 |
| Problems | p. 332 |
| Other Cutting and Joining Processes | |
| Introduction | p. 335 |
| Thermal Cutting Processes | p. 335 |
| Oxygen Cutting | |
| Electric Arc Cutting | |
| Plasma-arc Cutting (PAC) | |
| Metal Spraying | p. 341 |
| Principles and Methods | |
| Applications | |
| Surfacing and Hard-facing | p. 343 |
| Principles | |
| Procedures | |
| Braze Welding, Brazing, and Soldering | p. 344 |
| Braze Welding | |
| Brazing | |
| Soldering | |
| Process Automation | |
| Mechanical Fastening or Joining | p. 347 |
| Nonpermanent Fasteners | |
| Permanent Fasteners | |
| Adhesive Bonding | p. 349 |
| Questions | p. 349 |
| Quality Assurance | |
| Interchangeable Manufacture | p. 351 |
| Quality Assurance | p. 351 |
| Organizational Approaches | |
| Components of the Quality Assurance Function | |
| Statistical Methods | p. 355 |
| Common Causes of Variation | |
| Special Causes of Variation | |
| Statistical Process Control (SPC) Tools | |
| Process Capability | |
| Sampling Inspection | |
| Manufacturing Specifications | p. 363 |
| Tolerances | |
| Clearance | |
| Development of Manufacturing Specifications | |
| Questions | p. 371 |
| Problems | p. 372 |
| Measurement and Gaging | |
| Standards | p. 375 |
| Length Standard | |
| End Standards | |
| Instruments | p. 377 |
| Principal Technologies | |
| Selection | |
| Basic Linear Measuring Instruments | |
| Coordinate Measuring Machine (CMM) | p. 399 |
| Moving Bridge CMM | |
| Contacting Probes | |
| Noncontacting Sensors | |
| Automatic Gaging Systems | p. 402 |
| Measuring with Light Rays | p. 402 |
| Interferometry | |
| Optical Tooling | |
| Surface Quality | p. 406 |
| Surface Characteristics | |
| Surface Quality Specifications | |
| Surface Finish and Cost | |
| Measurement of Surface Finish | |
| Questions | p. 410 |
| Problems | p. 411 |
| How Metals Are Machined | |
| Importance of Metal Machining | p. 413 |
| Basic Processes | p. 413 |
| Surface Form Generation | |
| Machining Parameters | |
| Machine Tool History | |
| Mechanics of Metal Cutting | p. 416 |
| How a Tool Penetrates Metal | |
| Types of Chips | |
| Cutting Theory | |
| Oblique Cutting | |
| Metal Machining Conditions | p. 419 |
| Effect of Cutting Speed | |
| Effect of Feed | |
| Effect of Rake Angle | |
| Hot Machining | |
| Tool Wear | |
| Vibration and Chatter | |
| Metal-cutting Tools | p. 423 |
| Tool Material | |
| Shapes and Forms | |
| Cutting Fluids | p. 435 |
| Purpose | |
| Types | |
| Questions | p. 437 |
| Problems | p. 438 |
| Turning, Boring, and Facing | |
| Turning Operations | p. 441 |
| Plain or Straight Turning | |
| Chuck Work | |
| Taper Turning and Boring | |
| The Lathe | p. 442 |
| Principal Parts | |
| Power Feed | |
| Types | |
| Sizes | |
| Tracer Lathe | |
| Accessories And Attachments | p. 447 |
| Chucks | |
| Collets | |
| Centers and Drivers | |
| Rests | |
| Digital Readout Systems | |
| Attachments | |
| Lathe Operations | p. 452 |
| Practical Tolerances and Surface Finishes | |
| Production Turning Machines | p. 453 |
| Turret Lathes | |
| Automatic Turning Machines | |
| Machining Time and Material Removal Rate | p. 465 |
| Questions | p. 467 |
| Problems | p. 468 |
| Process Planning and Cost Evaluation | |
| Introduction | p. 471 |
| Preproduction Process Planning | p. 471 |
| Design for Manufacturability | |
| Planning Methods and Procedures | |
| Process Plan Development | p. 475 |
| Routing Information | |
| Process Mapping | |
| Operation Sheets | |
| Economics of Process Planning | p. 482 |
| General Considerations for Machine Tool Selection | p. 482 |
| Size and Capacity | |
| Strength and Power | |
| Other Considerations | |
| How Costs are Estimated and Compared | p. 484 |
| Productive Time | |
| How Operation Time is Estimated | |
| Comparison of Engine Lathe and Turret Lathe | |
| Finding the Lowest Cost for an Operation | |
| Equal Cost Point | |
| Special Considerations | |
| Questions | p. 491 |
| Problems | p. 492 |
| Drilling and Allied Operations | |
| Drills, Boring Tools, and Reamers | p. 496 |
| Common Drills | |
| Drill Sizes and Materials | |
| Drill Angles and Edges | |
| Deep Hole Drills | |
| Boring Tools | |
| Reamers | |
| Drilling Machines | p. 501 |
| Vertical Drill Presses | |
| Multispindle Drill Presses | |
| Radial Drill Presses | |
| Sizes of Drilling Machines | |
| Drilling Machine Accessories and Attachments | p. 506 |
| Toolholders and Drivers | |
| Multiple-spindle Drill Heads | |
| Workholding Devices | |
| Positioning Tables | |
| Fixtures and Jigs | |
| Boring Machines | p. 510 |
| Precision Production-boring Machines | |
| Precision Jig-boring Machines | |
| Jig Grinding Machines | |
| Jig Boring Operations | |
| Drilling and Boring Operations | p. 513 |
| Accuracy | |
| Speeds and Feeds | |
| Drilling Time and Cost | |
| Cutting Forces and Power | |
| Process Planning | p. 517 |
| Design for Manufacturing | |
| Process Selection and Operation Sequence | |
| Questions | p. 518 |
| Problems | p. 520 |
| Milling | |
| Evolution of Flat Surface Generating Processes | p. 523 |
| Milling Process | p. 523 |
| Milling Cutters and Drivers | p. 524 |
| Kinds of Cutters | |
| Arbors, Collets, and Adapters | |
| Milling Machines | p. 526 |
| General-purpose Machines | |
| Production Machines | |
| Machine Sizes | |
| Planer-type Machines | |
| Horizontal Boring, Drilling, and Milling Machines | |
| Machine Attachments | |
| Process Planning | p. 536 |
| Performance | |
| Economical Milling | |
| Speed, Feed, and Depth of Cut | |
| Estimating Time and Power | |
| Comparison with Other Operations | |
| Questions | p. 542 |
| Problems | p. 543 |
| Broaching and Sawing | |
| Broaching | p. 547 |
| Types of Broaches | |
| Pullers and Fixtures | |
| Machines | |
| Operations | |
| Broaching Compared with Other Operations | |
| Sawing | p. 557 |
| Saw Characteristics | |
| Machines | |
| Operations | |
| Questions | p. 563 |
| Problems | p. 563 |
| Abrasives, Grinding Wheels, and Grinding Operations | |
| Abrasives | p. 567 |
| Conventional Abrasives | |
| Superabrasives | |
| Grain Size | |
| Grinding Wheels | p. 570 |
| Properties | |
| Manufacture | |
| Other Abrasive Products | p. 573 |
| Coated Abrasives | |
| Polishing Wheels | |
| Abrasive Belts | |
| Grinding Operations | p. 574 |
| The Factors of Cost | |
| Balancing the Grinding Wheel | |
| Dressing and Truing the Grinding Wheel | |
| Theory | |
| Cutting Fluids | |
| Economics | |
| Questions | p. 585 |
| Problems | p. 587 |
| Grinding Machines and Methods | |
| Precision Grinders | p. 589 |
| Cylindrical Center-type Grinders | |
| Chucking Grinders | |
| Centerless Grinders | |
| Comparison of Center-type and Centerless Grinders | |
| Internal Grinding | |
| Surface Grinders | |
| CNC Grinding Machines | |
| Disk Grinders | |
| Thread Grinders | |
| Tool and Cutter Grinders | |
| Miscellaneous Grinders | |
| Abrasive Belt Grinders | |
| Nonprecision Grinders | p. 606 |
| Swing-frame Grinders | |
| Floor-stand and Bench Grinders | |
| Portable and Flexible-shaft Grinders | |
| Standard Tool and Cutter Grinders | |
| Grinding Compared with Other Operations | p. 606 |
| Questions | p. 609 |
| Problems | p. 610 |
| Ultra-Finishing Operations | |
| Lapping | p. 613 |
| Purpose | |
| Process | |
| Machines | |
| Honing | p. 615 |
| Purpose | |
| Process | |
| Machines | |
| Fine Grinding | |
| Microfinishing or Superfinishing | p. 618 |
| Purpose | |
| Process | |
| Machines and Attachments | |
| Ultrasonic Machining | |
| Burnishing and Bearingizing | p. 621 |
| Roller Burnishing | |
| Bearingizing | |
| Nonprecision Deburring and Finishing Processes | p. 623 |
| Polishing | |
| Buffing | |
| Power Brushing | |
| Tumbling and Vibratory Finishing | |
| Shot Blasting and Sandblasting | |
| Deburring | |
| Process Planning | p. 627 |
| Questions | p. 628 |
| Other Surface Enhancement Processes | |
| Cleaning | p. 631 |
| Cleaners | |
| Methods | |
| Pickling and Oxidizing | |
| Surface Coatings | p. 633 |
| Conversion Coatings | |
| Organic Coatings | |
| Hot-dip Plating | |
| Electroplating | |
| Electroforming | |
| Vacuum Deposition | |
| Other Metal-coating Processes | |
| Vitreous Coatings | |
| Green Manufacturing | p. 643 |
| Environmental Regulations | |
| Questions | p. 644 |
| Problems | p. 645 |
| Nontraditional Manufacturing Processes | |
| Chemical Machining Processes | p. 647 |
| Chemical Milling | |
| Photo-etching | |
| Thermochemical Machining | |
| Electrochemical/Electrolytic Machining Processes | p. 649 |
| Electrochemical Machining (ECM) | |
| Electrochemical Grinding | |
| Electrogel Machining (EGM) | |
| Thermal Machining Processes | p. 656 |
| Electron Beam Machining (EBM) | |
| Laser Beam Machining (LBM) | |
| Electrical Discharge Machining (EDM) | |
| Waterjet Machining (WJM) | p. 665 |
| Questions | p. 665 |
| Problems | p. 666 |
| Thread and Gear Manufacturing | |
| Screw Threads and Screws | p. 669 |
| Definitions | |
| Features | |
| Forms | |
| Standards | |
| Classes | |
| Measurement | |
| Making Screw Threads | |
| Gears | p. 683 |
| Gear Tooth Curves | |
| Elements of Gear Teeth | |
| Types of Gears | |
| Gear Manufacture | |
| Gear Inspection | |
| Questions | p. 704 |
| Problems | p. 705 |
| Manufacturing Systems | |
| Introduction | p. 709 |
| Manufacturing Systems | p. 709 |
| Classification | |
| Contemporary Manufacturing Technologies | p. 714 |
| Just-in-time (JIT) Manufacturing | |
| Flexible Manufacturing Systems (FMS) | |
| Coordinate Measuring Machines (CMMs) | |
| Group Technology (GT) | |
| Robotics | |
| Automation | |
| Emerging Technologies | p. 723 |
| Total Quality Management (TQM) | |
| Rapid Prototyping and Manufacturing | |
| Concurrent Engineering (CE) | |
| Components of an Integrated Manufacturing System | p. 728 |
| Manufacturing and Assembly Cells | |
| Cell Linkages | |
| Systems Integration Elements | |
| The New Manufacturing Enterprise Wheel | |
| Questions | p. 734 |
| Flexible Program Automation | |
| Classes of Automation | p. 739 |
| Fixed Program Automation | |
| Manned Cell Partial Automation | p. 749 |
| Material Handling | |
| Work Positioning and Clamping | |
| Inspection | |
| Machine Operation | |
| Digital Numerical Control | |
| Fuzzy Control Logic | |
| Unmanned Cell Automation | p. 754 |
| Machining Centers | |
| Decouplers | |
| Robots | |
| Automated Inspection | |
| Computer Integration | p. 759 |
| Computer-aided Design | |
| Computer-aided Process Planning | |
| Computer-aided Manufacturing | |
| Computer Integration of an Unmanned Cell | |
| Economic Justification of an Automated System | p. 762 |
| Questions | p. 764 |
| Problem | p. 764 |
| Numerical Control | |
| Introduction | p. 767 |
| Elements of Numerical Control | p. 767 |
| NC Operation | |
| The Coordinate System | |
| Positioning | |
| Closed- and Open-loop Systems | |
| Adaptive Control | |
| Numerical Control (NC) Systems | p. 777 |
| NC Machines | |
| Machining Centers | |
| NC Accuracy | |
| NC Adjuncts | |
| NC Measuring and Inspection Machines | |
| Programming for Numerical Control | p. 782 |
| Manual Programming | |
| Computer-assisted NC Programming | |
| Selection of a Programming Method | p. 801 |
| NC in the Total Manufacturing System | p. 802 |
| Economics of Numerical Control | p. 803 |
| Questions | p. 805 |
| Problems | p. 806 |
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