About the Book
The authors describe time-tested and modern methods of manufacturing engineering in this fourth edition. Every chapter has been reviewed and updated, as have all the bibliographies. 30% of the problems cited are also new.'
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.
