Fundamentals of Modern Manufacturing Materials, Processes, and Systems

Fundamentals of Modern Manufacturing is a balanced and qualitative examination of the materials, methods, and procedures of both traditional and recently-developed manufacturing principles and practices. This comprehensive textbook explores a broad range of essential points of learning, from long-established manufacturing processes and materials to contemporary electronics manufacturing technologies. An emphasis on the use of mathematical models and equations in manufacturing science presents readers with quantitative coverage of key topics, while plentiful tables, graphs, illustrations, and practice problems strengthen student comprehension and retention.

Now in its seventh edition, this leading textbook provides junior or senior-level engineering students in manufacturing courses with an inclusive and up-to-date treatment of the basic building blocks of modern manufacturing science. Coverage of core subject areas helps students understand the physical and mechanical properties of numerous manufacturing materials, the fundamentals of common manufacturing processes, the economic and quality control issues surrounding various processes, and recently developed and emerging manufacturing technologies. Thorough investigation of topics such as metal-casting and welding, material shaping processes, machining and cutting technology, and manufacturing systems and support helps students gain solid foundational knowledge of modern manufacturing.

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Student solution available in interactive e-text

1 Introduction and Overview of Manufacturing 1

1.1 What Is Manufacturing? 2

1.2 Materials in Manufacturing 8

1.3 Manufacturing Processes 10

1.4 Production Systems 17

1.5 Manufacturing Economics 20

Part I Material Properties and Product Attributes 27

2 The Nature of Materials 27

2.1 Atomic Structure and the Elements 27

2.2 Bonding between Atoms and Molecules 30

2.3 Crystalline Structures 32

2.4 Noncrystalline (Amorphous) Structures 37

2.5 Engineering Materials 38

3 Mechanical Properties of Materials 40

3.1 Stress–Strain Relationships 40

3.2 Hardness 53

3.3 Effect of Temperature on Properties 57

3.4 Fluid Properties 59

3.5 Viscoelastic Behavior of Polymers 61

4 Physical Properties of Materials 64

4.1 Volumetric and Melting Properties 64

4.2 Thermal Properties 67

4.3 Mass Diffusion 69

4.4 Electrical Properties 71

4.5 Electrochemical Processes 73

5 Dimensions, Surfaces, and Their Measurement 75

5.1 Dimensions, Tolerances, and Related Attributes 75

5.2 Conventional Measuring Instruments and Gages 76

5.3 Surfaces 84

5.4 Measurement of Surfaces 88

5.5 Effect of Manufacturing Processes 90

Part II Engineering Materials 93

6 Metals 93

6.1 Alloys and Phase Diagrams 94

6.2 Ferrous Metals 98

6.3 Nonferrous Metals 114

6.4 Superalloys 124

7 Ceramics 126

7.1 Structure and Properties of Ceramics 127

7.2 Traditional Ceramics 129

7.3 New Ceramics 131

7.4 Glass 134

7.5 Some Important Elements Related to Ceramics 138

8 Polymers 142

8.1 Fundamentals of Polymer Science and Technology 144

8.2 Thermoplastic Polymers 153

8.3 Thermosetting Polymers 157

8.4 Elastomers 160

8.5 Polymer Recycling and Biodegradability 166

9 Composite Materials 169

9.1 Technology and Classification of Composite Materials 170

9.2 Metal Matrix Composites 177

9.3 Ceramic Matrix Composites 179

9.4 Polymer Matrix Composites 180

Part III Solidification Processes 184

10 Fundamentals of Metal Casting 184

10.1 Overview of Casting Technology 186

10.2 Heating and Pouring 188

10.3 Solidification and Cooling 192

11 Metal Casting Processes 200

11.1 Sand Casting 200

11.2 Other Expendable-Mold Casting Processes 204

11.3 Permanent-Mold Casting Processes 209

11.4 Foundry Practice 218

11.5 Casting Quality 222

11.6 Castability and Casting Economics 224

11.7 Product Design Considerations 229

12 Glassworking 232

12.1 Raw Materials Preparation and Melting 232

12.2 Shaping Processes in Glassworking 233

12.3 Heat Treatment and Finishing 239

12.4 Product Design Considerations 240

13 Shaping Processes For Plastics 242

13.1 Properties of Polymer Melts 243

13.2 Extrusion 245

13.3 Production of Sheet and Film 257

13.4 Fiber and Filament Production (Spinning) 260

13.5 Coating Processes 261

13.6 Injection Molding 262

13.7 Compression and Transfer Molding 275

13.8 Blow Molding and Rotational Molding 277

13.9 Thermoforming 282

13.10 Casting 286

13.11 Polymer Foam Processing and Forming 287

13.12 Product Design Considerations 288

14 Processing of Polymer Matrix Composites and Rubber 291

14.1 Overview of PMC Processing 291

14.2 Open-Mold Processes 295

14.3 Closed-Mold Processes 299

14.4 Other PMC Shaping Processes 301

14.5 Rubber Processing and Shaping 305

14.6 Manufacture of Tires and Other Rubber Products 310

Part IV Particulate Processing of Metals and Ceramics 315

15 Powder Metallurgy 315

15.1 Characterization of Engineering Powders 317

15.2 Production of Metallic Powders 321

15.3 Conventional Pressing and Sintering 323

15.4 Alternative Pressing and Sintering Techniques 329

15.5 Powder Metallurgy Materials and Economics 331

15.6 Product Design Considerations in Powder Metallurgy 334

16 Processing of Ceramics and Cermets 338

16.1 Processing of Traditional Ceramics 338

16.2 Processing of New Ceramics 345

16.3 Processing of Cermets 348

16.4 Product Design Considerations 350

Part V Metal Forming and Sheet Metalworking 352

17 Fundamentals of Metal Forming 352

17.1 Overview of Metal Forming 352

17.2 Material Behavior in Metal Forming 355

17.3 Temperature in Metal Forming 356

17.4 Strain Rate Sensitivity 358

17.5 Friction and Lubrication in Metal Forming 360

18 Bulk Deformation Processes In Metal Working 362

18.1 Rolling 362

18.2 Forging 372

18.3 Extrusion 387

18.4 Wire and Bar Drawing 397

19 Sheet Metalworking 405

19.1 Cutting Operations 406

19.2 Bending Operations 412

19.3 Drawing 416

19.4 Equipment and Economics for Sheet-Metal Pressworking 423

19.5 Other Sheet-Metal-Forming Operations 432

19.6 Sheet-Metal Operations Not Performed on Presses 435

19.7 Bending of Tube Stock 440

Part VI Material Removal Processes 443

20 Theory of Metal Machining 443

20.1 Overview of Machining Technology 445

20.2 Theory of Chip Formation in Metal Machining 448

20.3 Force Relationships and the Merchant Equation 452

20.4 Power and Energy Relationships in Machining 458

20.5 Cutting Temperature 460

21 Machining Operations and Machine Tools 463

21.1 Machining and Part Geometry 463

21.2 Turning and Related Operations 466

21.3 Drilling and Related Operations 475

21.4 Milling 479

21.5 Machining Centers and Turning Centers 487

21.6 Other Machining Operations 489

21.7 Machining Operations for Special Geometries 494

21.8 High-Speed Machining 500

22 Cutting-Tool Technology 503

22.1 Tool Life 503

22.2 Tool Materials 509

22.3 Tool Geometry 517

22.4 Cutting Fluids 526

23 Economic and Product Design Considerations In Machining 530

23.1 Machinability 530

23.2 Tolerances and Surface Finish 531

23.3 Machining Economics 536

23.4 Product Design Considerations in Machining 543

24 Grinding and Other Abrasive Processes 546

24.1 Grinding 547

24.2 Related Abrasive Processes 562

25 Nontraditional Machining and Thermal Cutting Processes 567

25.1 Mechanical Energy Processes 568

25.2 Electrochemical Machining Processes 571

25.3 Thermal Energy Processes 575

25.4 Chemical Machining 584

25.5 Application Considerations 589

Part VII Property Enhancing and Surface Processing Operations 592

26 Heat Treatment of Metals 592

26.1 Annealing 592

26.2 Martensite Formation in Steel 593

26.3 Precipitation Hardening 597

26.4 Surface Hardening 598

26.5 Heat Treatment Methods and Facilities 599

27 Surface Processing Operations 602

27.1 Industrial Cleaning Processes 602

27.2 Diffusion and Ion Implantation 606

27.3 Plating and Related Processes 607

27.4 Conversion Coating 611

27.5 Vapor Deposition Processes 612

27.6 Organic Coatings 618

27.7 Porcelain Enameling and Other Ceramic Coatings 620

27.8 Thermal and Mechanical Coating Processes 621

Part VIII Joining and Assembly Processes 623

28 Fundamentals of Welding 623

28.1 Overview of Welding Technology 624

28.2 The Weld Joint 627

28.3 Physics of Welding 629

28.4 Features of a Fusion-Welded Joint 633

29 Welding Processes 635

29.1 Arc Welding 635

29.2 Resistance Welding 644

29.3 Oxyfuel Gas Welding 651

29.4 Other Fusion-Welding Processes 655

29.5 Solid-State Welding 657

29.6 Weld Quality 663

29.7 Weldability and Welding Economics 667

29.8 Design Considerations in Welding 670

30 Brazing, Soldering, and Adhesive Bonding 672

30.1 Brazing 672

30.2 Soldering 677

30.3 Adhesive Bonding 681

31 Mechanical Assembly 687

31.1 Threaded Fasteners 687

31.2 Rivets and Eyelets 694

31.3 Assembly Methods Based on Interference Fits 695

31.4 Other Mechanical Fastening Methods 698

31.5 Molding Inserts and Integral Fasteners 699

31.6 Design for Assembly 700

Part IX Special Processing and Assembly Technologies (Available in e-text for students) W-1

32 Additive Manufacturing W-1

(Available in e-text for students)

33 Processing of Integrated Circuits W-21

(Available in e-text for students)

34 Electronics Assembly and Packaging W-50

(Available in e-text for students)

35 Microfabrication Technologies W-71

(Available in e-text for students)

36 Nanofabrication Technologies W-83

(Available in e-text for students)

Part X Manufacturing Systems (Available in e-text for students) W-97

37 Automation Technologies For Manufacturing Systems W-97

(Available in e-text for students)

38 Integrated Manufacturing Systems W-122

(Available in e-text for students)

Part XI Manufacturing Support Systems W-144

39 Process Planning and Production Control W-144

(Available in e-text for students)

40 Quality Control and Inspection W-170

(Available in e-text for students)

Review Questions and Problems P-1

Index I-1