Table of Contents
(NOTE: Each chapter begins with an Introduction.)
General Introduction.
What Is Manufacturing? Examples of Manufactured Products. The
Design Process and Concurrent Engineering. Design for Manufacture,
Assembly, Disassembly, and Service. Selecting Materials. Selecting
Manufacturing Processes. Computer-Integrated Manufacturing. Quality
Assurance and Total Quality Management. Global Competitiveness and
Manufacturing Costs. Lean Production and Agile Manufacturing.
Environmentally-Conscious Design and Manufacturing. Product
Liability. Organization for Manufacture.
I. FUNDAMENTALS OF MATERIALS: THEIR BEHAVIOR AND
MANUFACTURING PROPERTIES.
1. The Structure of Metals.
The Crystal Structure of Metals. Deformation and Strength of Single
Crystals. Grains and Grain Boundaries. Plastic Deformation of
Polycrystalline Metals. Recovery, Recrystallization, and Grain
Growth. Cold-, Warm-, and Hot-Working.
2. Mechanical Behavior,
Testing, and Manufacturing Properties of Materials.
Tension. Compression. Tension. Bending (Flexure). Hardness.
Fatigue. Creep. Impact. Failure and Fracture of Materials in
Manufacturing and Service. Residual Stresses. Work, Heat, and
Temperature.
3. Physical Properties of Materials.
Density. Melting Point. Specific Heat. Thermal Conductivity.
Thermal Expansion. Electrical, Magnetic, and Optical Properties.
Corrosion Resistance.
4. Metal Alloys: Their Structure and
Strengthening by Heat Treatment.
Structure of Alloys. Phase Diagrams. The Iron-Carbon System. The
Iron-Iron Carbide Phase Diagram and the Development of
Microstructures in Steels. Cast Irons. Heat Treatment of Ferrous
Alloys. Hardenability of Ferrous Alloys. Heat Treatment of
Nonferrous Alloys and of Stainless Steels. Case Hardening.
Annealing. Heat-Treating Furnaces and Equipment. Design
Considerations for Heat Treating.
5. Ferrous Metals and Alloys:
Production, General Properties and Applications.
Production of Iron and Steel. Casting of Ingots. Continuous
Casting. Carbon and Alloy Steels. Stainless Steels. Tool and Die
Steels.
6. Nonferrous Metals and Alloys: Production, General
Properties, and Applications.
Aluminum and Aluminum Alloys. Magnesium and Magnesium Alloys.
Copper and Copper Alloys. Nickel and Nickel Alloys. Superalloys.
Titanium and Titanium Alloys. Refractory Metals and Alloys.
Beryllium. Zirconium. Low-Melting Alloys. Precious Metals.
Shape-Memory Alloys. Amorphous Alloys. Nanomaterials.
7.
Polymers: Structure, General Properties, and Applications.
The Structure of Polymers. Thermoplastics. Thermosetting Plastics.
Additives in Plastics. General Properties and Applications of
Thermoplastics. General Properties and Applications of
Thermosetting Plastics. Biodegradable Plastics. Elastomers
(Rubbers).
8. Ceramics, Graphite, and Diamond: Structure, General
Properties, and Applications.
The Structure of Ceramics. General Properties and Applications of
Ceramics. Glasses. Glass Ceramics. Graphite. Diamond.
9.
Composite Materials: Structure, General Properties, and
Applications.
The Structure of Reinforced Plastics. Properties of Reinforced
Plastics. Applications of Reinforced Plastics. Metal-Matrix
Composites. Ceramic-Matrix Composites. Other Composites.
II. METAL-CASTING PROCESSES AND EQUIPMENT.
10. Fundamentals of Metal Casting.
Solidification of Metals. Fluid Flow. Fluidity of Molten Metal.
Heat Transfer. Defects.
11. Metal-Casting Processes.
Sand Casting. Shell-Mold Casting. Expendable-Pattern Casting (Lost
Foam). Plaster-Mold Casting. Ceramic-Mold Casting. Investment
Casting. Vacuum Casting. Permanent-Mold Casting. Slush Casting.
Pressure Casting. Die Casting. Centrifugal Casting. Squeeze Casting
and Semisolid-Metal Forming. Casting Techniques for Single-Crystal
Components. Rapid Solidification (Amorphous Alloys). Inspection of
Castings. Melting Practice and Furnaces. Foundries and Foundry
Automation.
12. Metal Casting: Design, Materials, and
Economics.
Design Considerations. Casting Alloys. The Economics of Casting.
III. FORMING AND SHAPING PROCESSES AND EQUIPMENT.
13. Rolling of Metals.
Flat Rolling. Flat-Rolling Practice. Rolling Mills. Shape-Rolling
Operations. Production of Seamless Tubing and Pipe. Continuous
Casting and Rolling; Integrated Mills and Minimills.
14. Forging
of Metals.
Open-Die Forging. Impression-Die and Closed-Die Forging. Related
Forging Operations. Rotary Swaging. Forging Die-Design. Die
Materials and Lubrication. Forgeability. Forging Machines. Forging
Practice and Process Capabilities. Die Manufacturing Methods. Die
Failures. The Economics of Forging.
15. Extrusion and Drawing of
Metals.
The Extrusion Process. Extrusion Practice. Hot Extrusion. Cold
Extrusion. Impact Extrusion. Hydrostatic Extrusion. Extrusion
Defects. Extrusion Equipment. The Drawing Process. Drawing
Practice. Defects and Residual Stresses. Drawing Equipment.
16.
Sheet-Metal Forming Processes.
Shearing. Sheet-Metal Characteristics. Test Methods for Formability
of Sheet Metals. Bending Sheet and Plate. Common Bending
Operations. Tube Bending and Forming. Stretch Forming. Deep
Drawing. Rubber Forming. Spinning. Superplastic Forming. Explosive,
Magnetic-Pulse, Peen, and Other Forming Processes. The
Manufacturing of Honeycomb Structures. The Dent Resistance of
Sheet-Metal Parts. Equipment for Sheet-Metal Forming. The Economics
of Sheet-Metal Forming Processes.
17. Processing of Powder
Metals, Ceramics, Glass, and Superconductors.
Production of Metal Powders. Compaction of Metal Powders.
Sintering. Secondary and Finishing Operations. Design
Considerations for Powder Metallurgy. Process Capabilities.
Economics of Powder Metallurgy. Shaping Ceramics. Forming and
Shaping of Glass. Techniques for Strengthening and Treating Glass.
Design Considerations for Ceramics and Glasses. Processing of
Superconductors.
18. Forming and Shaping Plastics and Composite
Materials.
Extrusion. Injection Molding. Blow Molding. Rotational Molding.
Thermoforming. Compression Molding. Transfer Molding. Casting. Cold
Forming and Solid-Phase Forming. Processing Elastomers. Processing
Reinforced Plastics. Processing Metal-Matrix Composites. Processing
Ceramic-Matrix Composites. Design Considerations and Economics of
Forming and Shaping Plastics.
19. Rapid Prototyping
Operations.
Subtractive Processes. Additive Processes. Virtual Prototyping.
Applications.
IV. MATERIAL-REMOVAL PROCESSES AND MACHINES.
20. Fundamentals of Cutting.
The Mechanics of Chip Formation. The Types of Chips Produced in
Metal-Cutting. The Mechanics of Oblique Cutting. Cutting Forces and
Power. Temperatures in Cutting. Tool Life: Wear and Failure.
Surface Finish and Integrity. Machinability.
21. Cutting-Tool
Materials and Cutting Fluids.
Carbon and Medium-Alloy Steels. High-Speed Steels. Cast-Cobalt
Alloys. Carbides. Coated Tools. Alumina-Based Ceramics. Cubic Boron
Nitride. Silicon-Nitride Based Ceramics. Diamond.
Whisker-Reinforced Tool Materials. Cutting-Tool Reconditioning.
Cutting Fluids.
22. Machining Processes Used to Produce Round
Shapes.
Turning Parameters. Lathes and Lathe Operations. High-Speed
Machining, Ultraprecision Machining, and Hard Tuning. Cutting Screw
Threads. Boring and Boring Machines. Drilling and Drills. Drilling
Machines. Reaming and Reamers. Tapping and Taps. Design
Considerations for Drilling, Reaming and Tapping.
23. Machining
Processes Used to Produce Various Shapes.
Milling Operations. Milling Machines. Planning and Shaping.
Broaching and Broaching Machines. Sawing. Filing and Finishing.
Gear Manufacturing by Machining.
24. Machining and Turning
Centers, Machine-Tool Structures, and Machining Economics.
Machining and Turning Centers. Machine-Tool Structures. Vibration
and Chatter in Machining. Machining Economics.
25. Abrasive
Machining and Finishing Operations.
Abrasives. Bonded Abrasives (Grinding Wheels). The Grinding
Process. Grinding Wheel Wear. Grinding Operations and Machines.
Grinding Fluids. Design Considerations for Grinding. Ultrasonic
Machining. Finishing Operations. Deburring. Economics of Grinding
and Finishing Operations.
26. Advanced Machining Processes and
Nanofabrication.
Chemical Machining. Electrochemical Machining. Electrochemical
Grinding. Electrical-Discharge Machining. Wire EDM. Laser-Beam
Machining. Electron-Beam Machining and Plasma-Arc Cutting.
Water-Jet Machining. Abrasive-Jet Machining. Nanofabrication.
Micromachining. The Economics of Advanced Machining Processes.
JOINING PROCESSES AND EQUIPMENT.
27. Fusion Welding Processes.
Oxyfuel Gas Welding. Arc-Welding Processes: Consumable Electrode.
Electrodes. Arc-Welding Processes: Nonconsumable Electrode. Thermit
Welding. Electron-Beam Welding. Laser-Beam Welding. Cutting.
Welding Safety.
28. Solid-State Welding Processes.
Cold Welding. Ultrasonic Welding. Friction Welding. Resistance
Welding. Explosion Welding. Diffusion Bonding (Welding). Diffusion
Bonding/Superplastic Forming.
29. The Metallurgy of Welding:
Welding Design and Process Selection.
The Welded Joint. Weld Quality. Weldability. Testing Welded Joints.
Weld Design and Process Selection.
30. Brazing, Soldering,
Adhesive Bonding, and Mechanical Fastening Processes.
Brazing. Soldering. Adhesive Bonding. Mechanical Fastening. Joining
Plastics.
SURFACE TECHNOLOGY.
31. Surfaces: Their Nature, Roughness, and Measurement.
Surface Structure and Properties. Surface Integrity, Surface
Texture. Surface Roughness.
32. Tribology: Friction, Wear, and
Lubrication.
Friction in Metals. Friction in Plastics and Ceramics. Reducing
Friction. Friction Measurement. Wear. Wear of Plastics and
Ceramics. Wear Measurement. Lubrication. Metalworking Fluids. Solid
Lubricants. Conversion Coatings. Lubricant Selection.
33. Surface
Treatment, Coating and Cleaning.
Mechanical Surface Treatment and Coating. Case Hardening and Hard
Facing. Thermal Spraying. Vapor Deposition. Ion Implantation.
Diffusion Coating. Electroplating, Electroless Plating, and
Electroforming. Anodizing. Conversion Coating. Hot Dipping.
Porcelain Enameling, Ceramic Coating, and Organic Coatings. Diamond
Coating. Painting. Surface Texturing. Cleaning Surfaces.
34.
Fabrication of Microelectronic Devices.
Semiconductors and Silicon. Crystal Growing and Wafer Preparation.
Film Deposition. Oxidation. Lithography. Etching. Diffusion and Ion
Implantation. Metallization and Testing. Bonding and Packaging.
Yield and Reliability. Printed Circuit Boards.
VII. COMMON ASPECTS OF MANUFACTURING.
35. Engineering Metrology and Instrumentation.
Measurement Standards. Line-Graduated Instruments. Comparative
Length-Measuring Instruments. Measuring Straightness, Flatness,
Roundness, and Profile. Coordinate Measuring and Layout Machines.
Gages. Optical Instruments. Automated Measurements. General
Characteristics and Selection of Measuring Instruments. Geometric
Dimensioning and Tolerancing.
36. Quality Assurance, Testing, and
Inspection.
Product Quality. Quality Assurance. Total Quality Management.
Taguchi Methods. The ISO and QS Standards. Statistical Methods of
Quality Control. Statistical Process Control. Reliability.
Nondestructive Testing. Destructive Testing. Automated
Inspection.
37. Human Factors Engineering, Safety, and Product
Liability.
Human-Factors Engineering. Safety. Environmental Considerations.
Product Liability. Examples of Product Liability Claims.
VIII. MANUFACTURING IN A COMPETITIVE ENVIRONMENT.
38. Automation of Manufacturing Processes.
Automation. Numerical Control. Programming for Numerical Control.
Adaptive Control. Material Handling and Movement. Industrial
Robots. Sensor Technology. Flexible Fixturing. Design for Assembly,
Disassembly, and Service.
39. Computer-Integrated
Manufacturing.
Manufacturing Systems. Computer-Integrated Manufacturing.
Computer-Aided Design and Engineering. Computer Aided
Manufacturing. Computer-Aided Process Planning. Computer Simulation
of Manufacturing Processes and Systems. Group Technology. Cellular
Manufacturing. Flexible Manufacturing Systems. Just-in-Time
Production. Communications Networks in Manufacturing. Artificial
Intelligence. The Factory of the Future.
40. Competitive Aspects
of Manufacturing.
Selection of Materials. Product Design and Quantity of Material.
Substitution of Materials. Selection of Manufacturing Processes.
Process Capabilities. Manufacturing Costs. Value
Engineering.
Index.About the Author
PROFESSOR SEROPE KALPAKJIAN has been teaching at the
Illinois Institute of Technology since 1963. After graduating from
Robert College (with High Honors), Harvard University, and the
Massachusetts Institute of Technology, he joined Cincinnati
Milacron, Inc., where he was a research supervisor in charge of
advanced metal-forming processes. He has published numerous papers
and is the author of several articles in encyclopedias and
handbooks; he has also edited various volumes and serves on the
editorial boards of several journals and the Encyclopedia
Americana.
He is the author of three additional manufacturing books, two of
which received the M. Eugene Merchant Manufacturing Textbook Award.
He is a Life Fellow of the American Society of Mechanical
Engineers, Fellow and Life Member of ASM International, and Fell of
the Society of Manufacturing Engineers, and is a full member
(Emeritus) of the International Institution for Production
Engineering Research (CIRP). He is a founding member and a past
president of the North American manufacturing Research
Institution.
Professor Kalpakjian has received several awards: Citation by
the Forging Industry Educational and Research Foundation for best
paper (1966); Citation by the Society of Carbide and Tool Engineers
(1977); The "Excellence in Teaching Award" from the Illinois
Institute of Technology (1970); the "Centennial Medallion" by the
American Society of Mechanical Engineers (1980); the International
"Education Award" by the Society of Manufacturing Engineers (1989);
and the Albert Easton White Distinguished Teacher Award by the
American Society for Metals International (2000).
Dr. Steven R. Schmid is an Associate Professor in the
Department of Aerospace and Mechanical Engineering at the
University of Notre Dame, where he teaches and conducts research in
manufacturing, machine design, and tribology. As the Director of
the Manufacturing Tribology Laboratory at the university, he
oversees industry and governmentally funded research on a wide
variety of manufacturing topics, including tribological issues in
rolling, forging and sheet metal forming, polymer processing,
medical device design and manufacture, and nanomechanics.
He received his Bachelor's degree in Mechanical Engineering from
the Illinois Institute of Technology (with Honors) and Master's and
Ph.D. degrees, both in Mechanical Engineering, from Northwestern
University. Dr. Schmid is the recipient of a National Science
Foundation CAREERS Award and an ALCOA Foundation Young Faculty
Award. He has been a leading proponent for the integration of
research and engineering education; NSF has sponsored workshops on
this issue for which he has served as head of the steering
committee.
He is the author of over thirty technical papers in various
journals, has edited three conference proceedings, has co-authored
"Fundamentals of Machine Elements," and has contributed two
chapters to the CRC "Handbook of Modern Tribology." He serves on
the Tribology Division Executive Committee of the American Society
of Mechanical Engineers, and has held officer positions in the
Society of Manufacturing Engineers and the Society of Tribology and
Lubrication Engineers. He is a registered Professional Engineer an
a Certified Manufacturing Engineer.