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Preface iii 1 Introduction to DeGarmo's Materials and Processes in Manufacturing 1 1.1 Materials, Manufacturing, and the Standard of Living 1 1.2 Manufacturing and Production Systems 3 Review Questions 24 Problems 25 2 Properties of Materials 26 2.1 Introduction 26 2.2 Static Properties 28 2.3 Dynamic Properties 38 2.4 Temperature Effects (Both High and Low) 43 2.5 Machinability, Formability, and Weldability 46 2.6 Fracture Toughness and the Fracture Mechanics Approach 46 2.7 Physical Properties 48 2.8 Testing Standards and Testing Concerns 48 Review Questions 48 Problems 50 3 Nature of Materials 51 3.1 Structure-Property-Processing-Performance Relationships 51 3.2 The Structure of Atoms 52 3.3 Atomic Bonding 52 3.4 Secondary Bonds 53 3.5 Atom Arrangements in Materials 54 3.6 Crystal Structures 54 3.7 Development of a Grain Structure 56 3.8 Elastic Deformation 56 3.9 Plastic Deformation 57 3.10 Dislocation Theory of Slippage 58 3.11 Strain Hardening or Work Hardening 59 3.12 Plastic Deformation in Polycrystalline Material 60 3.13 Grain Shape and Anisotropic Properties 60 3.14 Fracture 61 3.15 Cold Working, Recrystallization, and Hot Working 61 3.16 Grain Growth 62 3.17 Alloys and Alloy Types 62 3.18 Atomic Structure and Electrical Properties 62 Review Questions 63 Problems 64 4 Equilibrium Phase Diagrams and the Iron-Carbon System 65 4.1 Introduction 65 4.2 Phases 65 4.3 Equilibrium Phase Diagrams 65 4.4 Iron-Carbon Equilibrium Diagram 71 4.5 Steels and the Simplified Iron-Carbon Diagram 72 4.6 Cast Irons 74 Review Questions 75 Problems 76 5 Heat Treatment 77 5.1 Introduction 77 5.2 Processing Heat Treatments 77 5.3 Heat Treatments Used to Increase Strength 80 5.4 Strengthening Heat Treatments for Nonferrous Metals 80 5.5 Strengthening Heat Treatments for Steel 83 5.6 Surface Hardening of Steel 94 5.7 Furnaces 96 5.8 Heat Treatment and Energy 97 Review Questions 98 Problems 99 6 Ferrous Metals and Alloys 101 6.1 Introduction to History-Dependent Materials 101 6.2 Ferrous Metals 101 6.3 Iron 102 6.4 Steel 102 6.5 Stainless Steels 113 6.6 Tool Steels 115 6.7 Cast Irons 117 6.8 Cast Steels 120 6.9 The Role of Processing on Cast Properties 120 Review Questions 121 Problems 122 7 Nonferrous Metals and Alloys 123 7.1 Introduction 123 7.2 Copper and Copper Alloys 123 7.3 Aluminum and Aluminum Alloys 128 7.4 Magnesium and Magnesium Alloys 134 7.5 Zinc and Zinc Alloys 136 7.6 Titanium and Titanium Alloys 137 7.7 Nickel-Based Alloys 138 7.8 Superalloys, Refractory Metals, and Other Materials Designed for High-Temperature Service 138 7.9 Lead and Tin and Their Alloys 141 7.10 Some Lesser-Known Metals and Alloys 141 7.11 Metallic Glasses 141 7.12 Graphite 142 7.13 Materials for Specific Applications 142 7.14 High Entropy Alloys 142 Review Questions 143 Problems 144 8 Nonmetallic Materials: Plastics, Elastomers, Ceramics, and Composites 145 8.1 Introduction 145 8.2 Plastics 145 8.3 Elastomers 156 8.4 Ceramics 159 8.5 Composite Materials 166 Review Questions 174 Problems 175 9 Material Selection 177 9.1 Introduction 177 9.2 Material Selection and Manufacturing Processes 179 9.3 The Design Process 179 9.4 Approaches to Material Selection 180 9.5 Additional Factors to Consider 183 9.6 Consideration of the Manufacturing Process 183 9.7 Ultimate Objective 184 9.8 Materials Substitution 185 9.9 Effect of Product Liability on Materials Selection 186 9.10 Aids to Material Selection 186 Review Questions 187 Problems 188 10 Fundamentals of Casting 191 10.1 Introduction to Materials Processing 191 10.2 Introduction to Casting 192 10.3 Casting Terminology 193 10.4 The Solidification Process 194 10.5 Patterns 202 10.6 Design Considerations in Castings 203 10.7 The Casting Industry 206 Review Questions 206 Problems 208 11 Expendable-Mold Casting Processes 209 11.1 Introduction 209 11.2 Sand Casting 209 11.3 Cores and Core Making 222 11.4 Other Expendable-Mold Processes with Multiple-Use Patterns 225 11.5 Expendable-Mold Processes Using Single-Use Patterns 226 11.6 Shakeout, Cleaning, and Finishing 232 11.7 Summary 232 Review Questions 232 Problems 234 12 Multiple-Use-Mold Casting Processes 235 12.1 Introduction 235 12.2 Permanent-Mold Casting 235 12.3 Die Casting 238 12.4 Squeeze Casting and Semisolid Casting 241 12.5 Centrifugal Casting 242 12.6 Continuous Casting 244 12.7 Melting 244 12.8 Pouring Practice 247 12.9 Cleaning, Finishing, Heat Treating, and Inspection 247 12.10 Automation in Foundry Operations 248 12.11 Process Selection 248 Review Questions 250 Problems 251 13 Fabrication of Plastics, Ceramics, and Composites 252 13.1 Introduction 252 13.2 Fabrication of Plastics 252 13.3 Processing of Rubber and Elastomers 262 13.4 Processing of Ceramics 263 13.5 Fabrication of Composite Materials 267 Review Questions 275 Problems 277 14 Fundamentals of Metal Forming 279 14.1 Introduction 279 14.2 Forming Processes: Independent Variables 280 14.3 Dependent Variables 281 14.4 Independent-Dependent Relationships 281 14.5 Process Modeling 282 14.6 General Parameters 282 14.7 Friction, Lubrication, and Wear under Metalworking Conditions 283 14.8 Temperature Concerns 284 14.9 Formability 290 Review Questions 290 Problems 292 15 Bulk Forming Processes 293 15.1 Introduction 293 15.2 Classification of Deformation Processes 293 15.3 Bulk Deformation Processes 294 15.4 Rolling 294 15.5 Forging 298 15.6 Extrusion 308 15.7 Wire, Rod, and Tube Drawing 312 15.8 Cold Forming, Cold Forging, and Impact Extrusion 314 15.9 Piercing 317 15.10 Other Squeezing Processes 318 15.11 Surface Improvement by Deformation Processing 320 Review Questions 321 Problems 322 16 Sheet-Forming Processes 325 16.1 Introduction 325 16.2 Shearing Operations 325 16.3 Bending 331 16.4 Drawing and Stretching Processes 338 16.5 Alternative Methods of Producing Sheet-Type Products 349 16.6 Seamed Pipe Manufacture 349 16.7 Presses 350 Review Questions 354 Problems 356 17 Powder Metallurgy (Particulate Processing) 357 17.1 Introduction 357 17.2 The Basic Process 357 17.3 Powder Manufacture 358 17.4 Powder Testing and Evaluation 359 17.5 Powder Mixing and Blending 360 17.6 Compacting 360 17.7 Sintering 363 17.8 Advances in Sintering (Shorter Time, Higher Density, Stronger Products) 364 17.9 Hot-Isostatic Pressing 365 17.10 Other Techniques to Produce High-Density P/M Products 366 17.11 Metal Injection Molding (MIM) 366 17.12 Secondary Operations 368 17.13 Properties of P/M Products 369 17.14 Design of Powder Metallurgy Parts 371 17.15 Powder Metallurgy Products 371 17.16 Advantages and Disadvantages of Powder Metallurgy 373 17.17 Process Summary 374 Review Questions 375 Problems 376 18 Additive Processes-Including 3-D Printing 377 18.1 Introduction 377 18.2 Layerwise Manufacturing 378 18.3 Liquid-Based Processes 381 18.4 Powder-Based Processes 383 18.5 Deposition-Based Processes 387 18.6 Uses and Applications 390 18.7 Pros, Cons and Current and Future Trends 393 18.8 Economic Considerations 395 Review Questions 396 Problems 397 19 Fundamentals of Machining/ Orthogonal Machining 398 19.1 Introduction 398 19.2 Fundamentals 398 19.3 Forces and Power in Machining 406 19.4 Orthogonal Machining (Two Forces) 409 19.5 Chip Thickness Ratio, rc 412 19.6 Mechanics of Machining (Statics) 413 19.7 Shear Strain, ?, and Shear Front Angle, ? 414 19.8 Mechanics of Machining (Dynamics) (Section courtsey of Dr. Elliot Stern) 416 Review Questions 422 Problems 423 20 Cutting Tool Materials 424 20.1 Introduction 424 20.2 Cutting Tool Materials 428 20.3 Tool Geometry 437 20.4 Tool-Coating Processes 438 20.5 Tool Failure and Tool Life 440 20.6 Taylor Tool Life 441 20.7 Cutting Fluids 446 20.8 Economics of Machining 446 Review Questions 448 Problems 449 21 Turning and Boring Processes 451 21.1 Introduction 451 21.2 Fundamentals of Turning, Boring, and Facing Turning 453 21.3 Lathe Design and Terminology 457 21.4 Cutting Tools for Lathes 462 21.5 Workholding in Lathes 466 Review Questions 470 Problems 471 22 Milling 472 22.1 Introduction 472 22.2 Fundamentals of Milling Processes 472 22.3 Milling Tools and Cutters 479 22.4 Machines for Milling 483 Review Questions 487 Problems 487 23 Drilling and Related Hole-Making Processes 488 23.1 Introduction 488 23.2 Fundamentals of the Drilling Process 489 23.3 Types of Drills 490 23.4 Tool Holders for Drills 500 23.5 Workholding for Drilling 501 23.6 Machine Tools for Drilling 501 23.7 Cutting Fluids for Drilling 504 23.8 Counterboring, Countersinking, and Spot Facing 506 23.9 Reaming 506 Review Questions 508 Problems 509 24 Sawing, Broaching, Shaping, and Filing Machining Processes 510 24.1 Introduction 510 24.2 Introduction to Sawing 510 24.3 Introduction to Broaching 518 24.4 Fundamentals of Broaching 520 24.5 Broaching Machines 525 24.6 Introduction to Shaping and Planing 525 24.7 Introduction to Filing 529 Review Questions 531 Problems 532 25 Abrasive Machining Processes 533 25.1 Introduction 533 25.2 Abrasives 535 25.3 Grinding Wheel Structure and Grade 538 25.4 Grinding Wheel Identification 542 25.5 Grinding Machines 546 25.6 Honing 553 25.7 Superfinishing 554 25.8 Free Abrasives 555 25.9 Design Considerations in Grinding 559 Review Questions 559 Problems 560 26 CNC Processes and Adaptive Control: A(4) and A(5) Levels of Automation 561 26.1 Introduction 561 26.2 Basic Principles of Numerical Control 561 26.3 CNC Part Programming 567 26.4 Interpolation and Adaptive Control 574 26.5 Machining Center Features and Trends 577 26.6 Summary 581 Review Questions 581 Problems 582 27 JIG and Fixture Design 584 27.1 Introduction 584 27.2 Conventional Fixture Design 584 27.3 Tool Design Steps 587 27.4 Clamping Considerations 588 27.5 Chip Disposal 589 27.6 Example of Jig Design 589 27.7 Types of Jigs 591 27.8 Conventional Fixtures 593 27.9 Modular Fixturing 593 27.10 Setup and Changeover 594 27.11 Clamps 599 27.12 Other Workholding Devices 599 27.13 Economic Justification of Jigs and Fixtures 602 Review Questions 603 Problems 603 28 Nontraditional Manufacturing Processes 605 28.1 Introduction 605 28.2 Chemical Machining Processes 607 28.3 Electrochemical Machining Processes 611 28.4 Electrical Discharge Machining 616 Review Questions 624 29 Fundamentals of Joining 626 29.1 Introduction to Consolidation Processes 626 29.2 Classification of Welding and Thermal Cutting Processes 627 29.3 Some Common Concerns 627 29.4 Types of Fusion Welds and Types of Joints 628 29.5 Design Considerations 630 29.6 Heat Effects 630 29.7 Weldability or Joinability 635 29.8 Summary 635 Review Questions 636 Problems 637 30 Gas Flame and Arc Processes 638 30.1 Oxyfuel-Gas Welding 638 30.2 Oxygen Torch Cutting 641 30.3 Flame Straightening 643 30.4 Arc Welding 643 30.5 Consumable-Electrode Arc Welding 644 30.6 Nonconsumable Electrode Arc Welding 650 30.7 Other Processes Involving Arcs 654 30.8 Arc Cutting 656 30.9 Metallurgical and Heat Effects in Thermal Cutting 658 30.10 Welding Equipment 658 30.11 Thermal Deburring 659 Review Questions 660 Problems 662 31 Resistance and Solid-State Welding Processes 663 31.1 Introduction 663 31.2 Theory of Resistance Welding 663 31.3 Resistance Welding Processes 665 31.4 Advantages and Limitations of Resistance Welding 669 31.5 Solid-State Welding Processes 669 Review Questions 677 Problems 678 32 Other Welding Processes, Brazing, and Soldering 679 32.1 Introduction 679 32.2 Other Welding and Cutting Processes 679 32.3 Surface Modification by Welding-Related Processes 686 32.4 Brazing 689 32.5 Soldering 696 Review Questions 699 Problems 700 33 Adhesive Bonding, Mechanical Fastening, and Joining of Non-Metals 701 33.1 Adhesive Bonding 701 33.2 Mechanical Fastening 708 33.3 Joining of Plastics 711 33.4 Joining of Ceramics and Glass 713 33.5 Joining of Composites 714 Review Questions 714 Problems 715 34 Surface Integrity and Finishing Processes 717 34.1 Introduction 717 34.2 Surface Integrity 717 34.3 Abrasive Cleaning and Finishing 724 34.4 Chemical Cleaning 729 34.5 Coatings 730 34.6 Vaporized Metal Coatings 738 34.7 Clad Materials 738 34.8 Textured Surfaces 738 34.9 Coil-Coated Sheets 738 34.10 Edge Finishing and Burr Removal 739 Review Questions 741 35 Nano and Micro-Manufacturing Processes 742 35.1 Introduction 742 35.2 Lithography 745 35.3 Micromachining Processes 748 35.4 Deposition Processes 751 35.5 How ICs are Made 757 35.6 Nano- and Micro-Scale Metrology 763 Review Questions 765 Problems 766 36 Measurement and Inspection 767 (online at www.wiley.com/college/black) 36.1 Introduction 767 36.2 Standards of Measurement 767 36.3 Allowance and Tolerance 770 36.4 Inspection Methods for Measurement 776 36.5 Measuring Instruments 777 36.6 Vision Systems 784 36.7 Coordinate Measuring Machines 785 36.8 Angle-measuring Instruments 787 36.9 Gages for Attributes Measuring 787 Review Questions 790 Problems 791 37 Nondestructive Examination (NDE) / Nondestructive Testing (NDT) 793 (online at www.wiley.com/college/black) 37.1 Destructive vs. Nondestructive Testing 793 37.2 Visual Inspection 795 37.3 Liquid Penetrant Inspection 795 37.4 Magnetic Particle Inspection 796 37.5 Ultrasonic Inspection 797 37.6 Radiography 799 37.7 Eddy-Current Testing 800 37.8 Acoustic Emission Monitoring 802 37.9 Other Methods of Nondestructive Testing and Inspection 803 37.10 Dormant vs. Critical Flaws 804 37.11 Current and Future Trends 804 Review Questions 804 Problems 805 38 Manufacturing Automation and Industrial Robots 807 (online at www.wiley.com/college/black) 38.1 Introduction 807 38.2 The A(4) Level of Automation 812 38.3 A(5) Level of Automation Requires Evaluation 818 38.4 Industrial Robotics 822 38.5 Computer-Integrated Manufacturing (CIM) 828 38.6 Computer-Aided Design 830 38.7 Computer-Aided Manufacturing 832 38.8 Summary 832 Review Questions 833 Advanced Topic 1 Process Capability and Quality Control 834 (online at www.wiley.com/college/black) A1.1 Introduction 834 A1.2 Determining Process Capability 835 A1.3 Introduction to Statistical Quality Control 841 A1.4 Sampling Errors 845 A1.5 Gage Capability 846 A1.6 Just in Time/Total Quality Control 846 A1.7 Six Sigma 855 A1.8 Summary 858 Review Questions 858 Problems 859 Advanced Topic 2 The Enterprise (Production System) 861 (online at www.wiley.com/college/black) A2.1 Introduction 861 A2.2 Typical Functional Areas in the Production System (PS) 861 Review Questions 876 Problems 877 Advanced Topic 3 Lean Engineering 878 (online at www.wiley.com/college/black) A3.1 Introduction 878 A3.2 The Lean Engineer 878 A3.3 The Lean Production System 879 A3.4 Linked-Cell Manufacturing System Design Rules 879 A3.5 Manufacturing System Designs 880 A3.6 Preliminary Steps to Lean Production 881 A3.7 Methodology for Implementation of Lean Production 882 A3.8 Design Rule MT < CT 894 A3.9 Decouplers 895 A3.10 Integrating Production Control 898 A3.11 Integrating Inventory Control 900 A3.12 Lean Manufacturing Cell Design 901 A3.13 Machine Tool Design for Lean Manufacturing Cells 904 A3.14 L-CMS Strategy 908 Review Questions 909 Problems 910 Advanced Topic 4 Mixed-Model Final Assembly 911 (online at www.wiley.com/college/black) A4.1 Introduction 911 A4.2 History 911 A4.3 Mixed-Model Final Assembly 912 A4.4 An Example of MMFA 913 A4.5 Key Enabling Systems 913 A4.6 Manual Assembly Line Balancing 915 A4.7 Sequencing 917 A4.8 Quality in Mixed-Model Final Assembly 918 A4.9 Examples of Assembly Aids/Poka-Yoke(Error-Proofing) Applications 920 Review Questions 921 Problems 922 Index I1 Selected References For Additional Study S1

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