Materials and Processes in Manufacturing

ISBN-10: 0470924675

ISBN-13: 9780470924679

Edition: 11th 2012

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The new edition of DeGarmo#x19;s Materials and Processes in Manufacturing focuses on updates and more coverage of non-metallic materials, sustainability, lean manufacturing, rapid prototyping and revised end of chapter and case study content. It emphasizes application and design, present mathematical models and analytic equations sparingly and uses case studies to highlight real world examples of manufacturing. Other revisions and updates include the addition of frontend Learning Objectives; elimination of weak problems and addition of new problems; more relevant and current case studies as well as additional new ones where appropriate; new chapter on Rapid Prototyping; expanded coverage of non-metallic materials such as composites, polymers, etc. ; a discussion about sustainability and green, and engineering and how it relates to manufacturing; coverage of lean manufacturing and production; and updated references and chapter summaries.
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Book details

List price: $249.95
Edition: 11th
Copyright year: 2012
Publisher: John Wiley & Sons, Incorporated
Publication date: 8/30/2011
Binding: Hardcover
Pages: 1184
Size: 9.00" wide x 11.00" long x 2.00" tall
Weight: 5.830
Language: English

Introduction to DeGarmo's Materials and Processes in Manufacturing
Materials, Manufacturing, and the Standard of Living
Manufacturing and Production Systems
Case Study Famous Manufacturing Engineers
Manufacturing Systems Design
Manufacturing Systems
Control of the Manufacturing System
Classification of Manufacturing Systems
Summary of Factory Designs
Case Study Jury Duty for an Engineer
Properties of Materials
Static Properties
Dynamic Properties
Temperature Effects (Both High and Low)
Machinability, Formability, and Weldability
Fracture Toughness and the Fracture Mechanics Approach
Physical Properties
Testing Standards and Testing Concerns
Case Study Separation of Mixed Materials
Nature of Metals and Alloys
Structure-Property-Processing-Performance Relationships
The Structure of Atoms
Atomic Bonding
Secondary Bonds
Atom Arrangements in Materials
Crystal Structures of Metals
Development of a Grain Structure
Elastic Deformation
Plastic Deformation
Dislocation Theory of Slippage
Strain Hardening or Work Hardening
Plastic Deformation in Polycrystalline Metals
Grain Shape and Anisotropic Properties
Fracture of Metals
Cold Working, Recrystallization, and Hot Working
Grain Growth
Alloys and Alloy Types
Atomic Structure and Electrical Properties
Equilibrium Phase Diagrams and the Iron-Carbon System
Equilibrium Phase Diagrams
Iron-Carbon Equilibrium Diagram
Steels and the Simplified Iron-Carbon Diagram
Cast Irons
Case Study Fish Hooks
Heat Treatment
Processing Heat Treatments
Heat Treatments Used to Increase Strength
Strengthening Heat Treatments for Nonferrous Metals
Strengthening Heat Treatments for Steel
Surface Hardening of Steel
Heat Treatment and Energy
Case Study A Carpenter's Claw Hammer
Ferrous Metals and Alloys
Introduction to History-Dependent Materials
Ferrous Metals
Stainless Steels
Tool Steels
Cast Irons
Cast Steels
The Role of Processing on Cast Properties
Case Study The Paper Clip
Nonferrous Metals and Alloys
Copper and Copper Alloys
Aluminum and Aluminum Alloys
Magnesium and Magnesium Alloys
Zinc and Zinc Alloys
Titanium and Titanium Alloys
Nickel-Based Alloys
Superalloys, Refractory Metals, and Other Materials Designed for High-Temperature Service
Lead and Tin, and Their Alloys
Some Lesser-Known Metals and Alloys
Metallic Glasses
Case Study Hip Replacement Prosthetics
Nonmetallic Materials: Plastics, Elastomers, Ceramics, and Composites
Composite Materials
Case Study Lightweight Armor
Material Selection
Material Selection and Manufacturing Processes
The Design Process
Approaches to Material Selection
Additional Factors to Consider
Consideration of the Manufacturing Process
Ultimate Objective
Materials Substitution
Effect of Product Liability on Materials Selection
Aids to Material Selection
Case Study Material Selection
Fundamentals of Casting
Introduction to Materials Processing
Introduction to Casting
Casting Terminology
The Solidification Process
Design Considerations in Castings
The Casting Industry
Case Study The Cast Oil-Field Fitting
Expendable-Mold Casting Processes
Sand Casting
Cores and Core Making
Other Expendable-Mold Processes with Multiple-Use Patterns
Expendable-Mold Processes Using Single-Use Patterns
Shakeout, Cleaning, and Finishing
Case Study Movable and Fixed Jaw Pieces for a Heavy-Duty Bench Vise
Multiple-Use-Mold Casting Processes
Permanent-Mold Casting
Die Casting
Squeeze Casting and Semisolid Casting
Centrifugal Casting
Continuous Casting
Pouring Practice
Cleaning, Finishing, and Heat Treating of Castings
Automation in Foundry Operations
Process Selection
Case Study Baseplate for a Household Steam Iron
Fabrication of Plastics, Ceramics, and Composites
Fabrication of Plastics
Processing of Rubber and Elastomers
Processing of Ceramics
Fabrication of Composite Materials
Case Study Automotive and Light Truck Fuel Tanks
Fundamentals of Metal Forming
Forming Processes: Independent Variables
Dependent Variables
Independent-Dependent Relationships
Process Modeling
General Parameters
Friction and Lubrication Under Metalworking Conditions
Temperature Concerns
Case Study Interior Tub of a Top-Loading Washing Machine
Bulk-Forming Processes
Classification of Deformation Processes
Bulk Deformation Processes
Wire, Rod, and Tube Drawing
Cold Forming, Cold Forging, and Impact Extrusion
Other Squeezing Processes
Surface Improvement by Deformation Processing
Case Study Handle and Body of a Large Ratchet Wrench
Sheet-Forming Processes
Shearing Operations
Drawing and Stretching Processes
Alternative Methods of Producing Sheet-Type Products
Pipe Manufacture
Case Study Automotive Body Panels
Powder Metallurgy
The Basic Process
Powder Manufacture
Microcrystalline and Amorphous Material Produced by Rapid Cooling
Powder Testing and Evaluation
Powder Mixing and Blending
Recent Advances in Sintering
Hot-Isostatic Pressing
Other Techniques to Produce High-Density Powder Metallurgy Products
Metal Injection Molding or Powder Injection Molding
Secondary Operations
Properties of Powder Metallurgy Products
Design of Powder Metallurgy Parts
Powder Metallurgy Products
Advantages and Disadvantages of Powder Metallurgy
Process Summary
Case Study Steering Gear for a Riding Lawn Mower/Garden Tractor
Additive Processes: Rapid Prototyping and Direct-Digital Manufacturing
Rapid Prototyping and Direct-Digital Manufacturing
Layerwise Manufacturing
Liquid-Based Processes
Powder-Based Processes
Deposition-Based Processes
Uses and Applications
Pros, Cons, and Current and Future Trends
Economic Considerations
Fundamentals of Machining/Orthogonal Machining
Forces and Power in Machining
Orthogonal Machining (Two Forces)
Chip Thickness Ratio
Mechanics of Machining (Statics)
Shear Strain, g, and Shear Front Angle
Mechanics of Machining (Dynamics)
Case Study Orthogonal Plate Machining Experiment at Auburn University
Cutting Tools for Machining
Cutting Tool Materials
Tool Geometry
Tool-Coating Processes
Tool Failure and Tool Life
Flank Wear
Cutting Fluids
Economics of Machining
Case Study Comparing Tool Materials Based on Tool Life
Turning and Boring Processes
Fundamentals of Turning, Boring, and Facing Turning
Lathe Design and Terminology
Cutting Tools for Lathes
Workholding in Lathes
Case Study Estimating the Machining Time for Turning
Drilling and Related Hole-Making Processes
Fundamentals of the Drilling Process
Types of Drills
Tool Holders for Drills
Workholding for Drilling
Machine Tools for Drilling
Cutting Fluids for Drilling
Counterboring, Countersinking, and Spot Facing
Case Study Bolt-down Leg on a Casting
Fundamentals of Milling Processes
Milling Tools and Cutters
Machines for Milling
Case Study HSS versus Tungsten Carbide Milling
Sawing, Broaching, and Other Machining Processes
Introduction to Sawing
Introduction to Broaching
Fundamentals of Broaching
Broaching Machines
Introduction to Shaping and Planing
Introduction to Filing
Case Study Cost Estimating-Planing vs. Milling
Abrasive Machining Processes
Grinding Wheel Structure and Grade
Grinding Wheel Identification
Grinding Machines
Free Abrasives
Design Considerations In Grinding
Case Study Process Planning for the MfE
Workholding Devices for Machine Tools
Conventional Fixture Design
Tool Design Steps
Clamping Considerations
Chip Disposal
Unloading and Loading Time
Example of Jig Design
Types of Jigs
Conventional Fixtures
Modular Fixturing
Setup and Changeover
Other Workholding Devices
Economic Justification of Jigs and Fixtures
Case Study Fixture versus No Fixture in Milling
Nontraditional Manufacturing Processes
Chemical Machining Processes
Electrochemical Machining Processes
Electrical Discharge Machining
Case Study Vented Cap Screws
Lean Engineering
The Lean Engineer
The Lean Production System
Linked-Cell Manufacturing System Design Rules
Manufacturing System Designs
Preliminary Steps to Lean Production
Methodology for Implementation of Lean Production
Design Rule MT < CT
Integrating Production Control
Integrating Inventory Control
Lean Manufacturing Cell Design
Machine Tool Design for Lean Manufacturing Cells
L-CMS Strategy
Case Study Cycle Time for a Manufacturing Cell
Fundamentals of Joining
Introduction to Consolidation Processes
Classification of Welding and Thermal Cutting Processes
Some Common Concerns
Types of Fusion Welds and Types of Joints
Design Considerations
Heat Effects
Weldability or Joinability
Gas Flame and Arc Processes
Oxyfuel-Gas Welding
Oxygen Torch Cutting
Flame Straightening
Arc Welding
Consumable-Electrode Arc Welding
Nonconsumable-Electrode Arc Welding
Welding Equipment
Arc Cutting
Metallurgical and Heat Effects in Thermal Cutting
Case Study Bicycle Frame Construction and Repair
Resistance- and Solid-State Welding Processes
Theory of Resistance Welding
Resistance-Welding Processes
Advantages and Limitations of Resistance Welding
Solid-State Welding Processes
Case Study Manufacture of an Automobile Muffler
Other Welding Processes, Brazing, and Soldering
Other Welding and Cutting Processes
Surface Modification by Welding-Related Processes
Case Study Impeller of a Pharmaceutical Company Industrial Shredder/Disposal
Adhesive Bonding, Mechanical Fastening, and Joining of Nonmetals
Adhesive Bonding
Mechanical Fastening
Joining of Plastics
Joining of Ceramics and Glass
Joining of Composites
Case Study Golf Club Heads with Insert
Measurement and Inspection
Standards of Measurement
Allowance and Tolerance
Inspection Methods for Measurement
Measuring Instruments
Vision Systems for Measurement
Coordinate Measuring Machines
Angle-Measuring Instruments
Gages for Attributes Measuring
Case Study Measuring An Angle
Quality Engineering
Determining Process Capability
Introduction to Statistical Quality Control
Sampling Errors
Gage Capability
Just in Time/Total Quality Control
Six Sigma
Case Study Boring QC Chart Blunders
Surface Engineering
Abrasive Cleaning and Finishing
Chemical Cleaning
Vaporized Metal Coatings
Clad Materials
Textured Surfaces
Coil-Coated Sheets
Edge Finishing and Burrs
Case Study Dana Lynn's Fatigue Lesson
Micro/Meso/Nano Fabrication Processes
Additive Processes
Metrology at the Micro/Meso/Nano Level
Manufacturing Automation
The A(4) Level of Automation
A(5) Evaluation or Adaptive Control
A(6) Level of Automation and Beyond
Computer-Integrated Manufacturing Automation
Computer-Aided Design
Computer-Aided Manufacturing
NC/CNC Processes and Adaptive Control: A(4) and A(5) Levels of Automation
Basic Principles of Numerical Control
Machining Center Features and Trends
Ultra-High-Speed Machining Centers
Microelectric Manufacturing and Assembly
How Electronic Products Are Made
How Integrated Circuits Are Made
How the Silicon Wafer Is Made
Fabricating Integrated Circuits on Silicon Wafers
Thin-Film Deposition
Integrated Circuit Packaging
Printed Circuit Boards
Electronic Assembly
Thread and Gear Manufacturing
Thread Making
Internal Thread CuttingTapping
Thread Milling
Thread Grinding
Thread Rolling
Gear Making
Gear Types
Gear Manufacturing
Machining of Gears
Gear Finishing
Gear Inspection
Nondestructive Inspection and Testing
Destructive versus Nondestructive Testing 1215 (web-based chapter)
Other Methods of Nondestructive Testing and Inspection
The Enterprise (Production Systems) 1230 (web-based chapter)
Axiomatic Design of Systems
Enterprise System Design Principles
Functional Areas in the Production System
Human Resources (Personnel) Department
Index I-2
Selected References for Additional Study S1
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