About the Book
Manufacturing Engineering and Technology offers thorough, up-to-date coverage of manufacturing science, engineering and technology, and will help you understand the vital importance of manufacturing in the modern global economy. It emphasizes the interconnectedness of every manufacturing activity, from complex interactions between materials to design, process and operations. Extensive questions and problems explore viable solutions to a wide variety of challenges, encouraging you to describe and assess both the capabilities and limitations involved. Examples and case studies depict real-world applications of the topics described.
The 9th Edition is fully updated, with many new topics and illustrations; expands Questions, Qualitative Projects and Quantitative Projects, and Design Problems; examines manufacturing in the context of climate change and the post-COVID world; and much more.
Table of Contents:
NOTE: Each chapter concludes with Summary, Bibliography, Review Questions, Qualitative Problems, Quantitative Problems, Synthesis, Design, and Projects. I: Fundamentals of Materials: Behavior and Manufacturing Properties - 1: The Structure of Metals
- 1.1: Introduction
- 1.2: Types of Atomic Bonds
- 1.3: The Crystal Structure of Metals
- 1.4: Deformation and Strength of Single Crystals
- 1.5: Grains and Grain Boundaries
- 1.6: Plastic Deformation of Polycrystalline Metals
- 1.7: Recovery, Recrystallization, and Grain Growth
- 1.8: Cold, Warm, and Hot Working
- 2: Mechanical Behavior, Testing, and Manufacturing Properties of Materials
- 2.1: Introduction
- 2.2: Tension
- 2.3: Compression
- 2.4: Torsion
- 2.5: Bending (Flexure)
- 2.6: Hardness
- 2.7: Fatigue
- 2.8: Creep
- 2.9: Impact
- 2.10: Failure and Fracture of Materials
- 2.11: Residual Stresses
- 2.12: Work, Heat, and Temperature
- 3: Physical Properties of Materials
- 3.1: Introduction
- 3.2: Density
- 3.3: Melting Point
- 3.4: Specific Heat
- 3.5: Thermal Conductivity
- 3.6: Thermal Expansion
- 3.7: Electrical, Magnetic, and Optical Properties
- 3.8 : Corrosion Resistance
- 4: Metal Alloys: Their Structure and Strengthening by Heat Treatment
- 4.1: Introduction
- 4.2: Structure of Alloys
- 4.3: Phase Diagrams
- 4.4: The Iron–Carbon System
- 4.5: The Iron–Iron-carbide Phase Diagram and the Development of Microstructures in Steels
- 4.6: Cast Irons
- 4.7: Heat Treatment of Ferrous Alloys
- 4.8: Hardenability of Ferrous Alloys
- 4.9: Heat Treatment of Nonferrous Alloys and Stainless Steels
- 4.10: Case Hardening
- 4.11: Annealing
- 4.12: Heat Treating Furnaces and Equipment
- 4.13: Design Considerations for Heat Treating
- 5: Ferrous Metals and Alloys: Production, General Properties, and Applications
- 5.1: Introduction
- 5.2: Production of Iron and Steel
- 5.3: Casting of Ingots
- 5.4: Continuous Casting
- 5.5: Carbon and Alloy Steels
- 5.6: Stainless Steels
- 5.7: Tool and Die Steels
- 6: Nonferrous Metals and Alloys: Production, General Properties, and Applications
- 6.1: Introduction
- 6.2: Aluminum and Aluminum Alloys
- 6.3: Magnesium and Magnesium Alloys
- 6.4: Copper and Copper Alloys
- 6.5: Nickel and Nickel Alloys
- 6.6: Superalloys
- 6.7: Titanium and Titanium Alloys
- 6.8: Refractory Metals and Alloys
- 6.9: Beryllium
- 6.10: Zirconium
- 6.11: Lithium
- 6.12: Low-melting Alloys
- 6.13: Precious Metals
- 6.14: Shape-memory Alloys (Smart Materials)
- 6.15: Amorphous Alloys (Metallic Glasses)
- 6.16: Metal Foams and Metamaterials
- 6.17: Rare Earth Metals
- 7: Polymers: Structure, General Properties, and Applications
- 7.1: Introduction
- 7.2: The Structure of Polymers
- 7.3: Thermoplastics
- 7.4: Thermosetting Plastics
- 7.5: Additives in Plastics
- 7.6: General Properties and Applications of Thermoplastics
- 7.7: General Properties and Applications of Thermosetting Plastics
- 7.8: Biodegradable Plastics
- 7.9: Elastomers (Rubbers)
- 7.10: Gels
- 8: Ceramics, Glass, Graphite, Diamond, and Nanomaterials: Structure, General Properties, and Applications
- 8.1: Introduction
- 8.2: The Structure of Ceramics
- 8.3: General Properties and Applications of Ceramics
- 8.4: Glasses
- 8.5: Glass Ceramics
- 8.6: Graphite
- 8.7: Diamond
- 8.8: Nanomaterials
- 9: Composite Materials: Structure, General Properties, and Applications
- 9.1: Introduction
- 9.2: The Structure of Reinforced Plastics
- 9.3: Properties of Reinforced Plastics
- 9.4: Applications of Reinforced Plastics
- 9.5: Metal-matrix Composites
- 9.6: Ceramic-matrix Composites
- 9.7: Other Composites
II: Metal-casting Processes and Equipment - 10: Fundamentals of Metal Casting
- 10.1: Introduction
- 10.2: Solidification of Metals
- 10.3: Fluid Flow
- 10.4: Fluidity of Molten Metal
- 10.5: Heat Transfer
- 10.6: Defects
- 11: Metal-casting Processes and Equipment
- 11.1: Introduction
- 11.2: Expendable-mold, Permanent-pattern Casting Processes
- 11.3: Expendable-mold, Expendable-pattern Casting Processes
- 11.4: Permanent-mold Casting Processes
- 11.5: Casting Techniques for Single-crystal Components
- 11.6: Rapid Solidification
- 11.7: Inspection of Castings
- 11.8: Melting Practice and Furnaces
- 11.9: Foundries and Foundry Automation
- 12: Metal Casting: Design, Materials, and Economics
- 12.1: Introduction
- 12.2: Design Considerations in Casting
- 12.3: Casting Alloys
- 12.4: Economics of Casting
III: Forming and Shaping Processes and Equipment - 13: Metal-rolling Processes and Equipment
- 13.1: Introduction
- 13.2: The Flat-rolling Process
- 13.3: Flat-rolling Practice
- 13.4: Rolling Mills
- 13.5: Various Rolling Processes and Mills
- 14: Metal-forging Processes and Equipment
- 14.1: Introduction
- 14.2: Open-die Forging
- 14.3: Impression-die and Closed-die Forging
- 14.4: Various Forging Operations
- 14.5: Forgeability of Metals; Forging Defects
- 14.6: Die Design, Die Materials, and Lubrication
- 14.7: Die-manufacturing Methods and Die Failures
- 14.8: Forging Machines
- 14.9: Economics of Forging
- 15: Metal Extrusion and Drawing Processes and Equipment
- 15.1: Introduction
- 15.2: The Extrusion Process
- 15.3: Hot Extrusion
- 15.4: Cold Extrusion
- 15.5: Extrusion Defects
- 15.6: Design Considerations
- 15.7: Extrusion Equipment
- 15.8: The Drawing Process
- 15.9: Drawing Practice
- 15.10: Drawing Defects and Residual Stresses
- 15.11: Drawing Equipment
- 16 : Sheet-Metal Forming Processes and Equipment
- 16.1: Introduction
- 16.2: Shearing
- 16.3: Sheet-metal Characteristics and Formability
- 16.4: Formability Tests for Sheet Metals
- 16.5: Bending Sheets, Plates, and Tubes
- 16.6: Miscellaneous Bending and Related Forming Operations
- 16.7: Deep Drawing
- 16.8: Rubber Forming and Hydroforming
- 16.9: Spinning
- 16.10: Superplastic Forming
- 16.11: Hot Stamping
- 16.12: Specialized Forming Processes
- 16.13: Manufacturing of Metal Honeycomb Structures
- 16.14: Design Considerations in Sheet-metal Forming
- 16.15: Equipment for Sheet-metal Forming
- 16.16: Economics of Sheet-forming Operations
- 17: Powder-Metal Processes and Equipment
- 17.1: Introduction
- 17.2: Production of Metal Powders
- 17.3: Compaction of Metal Powders
- 17.4: Sintering
- 17.5: Secondary and Finishing Operations
- 17.6: Design Considerations
- 17.7: Economics of Powder Metallurgy
- 18: Ceramics, Glasses, and Superconductors: Processing and Equipment
- 18.1: Introduction
- 18.2: Shaping Ceramics
- 18.3: Forming and Shaping of Glass
- 18.4: Techniques for Strengthening and Annealing Glass
- 18.5: Design Considerations for Ceramics and Glasses
- 18.6: Processing of Superconductors
- 19: Plastics and Composite Materials: Forming and Shaping
- 19.1: Introduction
- 19.2: Extrusion
- 19.3: Injection Molding
- 19.4: Blow Molding
- 19.5: Rotational Molding
- 19.6: Thermoforming
- 19.7: Compression Molding
- 19.8: Transfer Molding
- 19.9: Casting
- 19.10: Foam Molding
- 19.11: Cold Forming and Solid-phase Forming
- 19.12: Processing Elastomers
- 19.13: Processing Polymer-Matrix Composites
- 19.14: Processing Metal-Matrix and Ceramic-Matrix Composites
- 19.15: Design Considerations
- 19.16: Economics of Processing Plastics and Composite Materials
- 20: Additive Manufacturing
- 20.1: Introduction
- 20.2: Additive Manufacturing Methodology
- 20.3: Material Extrusion
- 20.4: Vat Polymerization
- 20.5: Material Jetting
- 20.6: Binder Jetting
- 20.7: Powder Bed Fusion
- 20.8: Sheet Lamination
- 20.9: Directed Energy Deposition
- 20.10: Miscellaneous Processes
- 20.11: Direct Manufacturing and Rapid Tooling
- 20.12: Design for Additive Manufacturing
- 20.13: Additive Manufacturing Economics
IV: Machining Processes and Machine Tools - 21: Fundamentals of Machining
- 21.1: Introduction
- 21.2: Mechanics of Cutting
- 21.3: Cutting Forces and Power
- 21.4: Temperatures in Cutting
- 21.5: Tool Life: Wear and Failure
- 21.6: Surface Finis
- 21.7: Machinability
- 22: Cutting-Tool Materials and Cutting Fluids
- 22.1: Introduction
- 22.2: High-speed Steels
- 22.3: Cast-cobalt Alloys
- 22.4: Carbides
- 22.5: Coated Tools
- 22.6: Alumina-based Ceramics
- 22.7: Cubic Boron Nitride
- 22.8: Silicon-Nitride-based Ceramics
- 22.9: Diamond
- 22.10: Whisker-reinforced Materials and Nanomaterials
- 22.11: Tool Costs and Reconditioning of Tools
- 22.12: Cutting Fluids
- 23: Machining Processes: Turning and Hole Making
- 23.1: Introduction
- 23.2: The Turning Process
- 23.3: Lathes and Lathe Operations
- 23.4: Boring and Boring Machines
- 23.5: Drilling, Drills, and Drilling Machines
- 23.6: Reaming and Reamers
- 23.7: Tapping and Taps
- 24: Machining Processes: Milling, Broaching, Sawing, Filing, and Gear Manufacturing
- 24.1: Introduction
- 24.2: Milling and Milling Machines
- 24.3: Planing and Shaping
- 24.4: Broaching and Broaching Machines
- 24.5: Sawing
- 24.6: Filing
- 24.7: Gear Manufacturing by Machining
- 25: Machining Centers, Machine-tool Structures, and Machining
- 25.1: Introduction
- 25.2: Machining Centers
- 25.3: Machine-tool Structures
- 25.4: Vibration and Chatter in Machining Operations
- 25.5: High-speed Machining
- 25.6: Hard Machining
- 25.7: Ultraprecision Machining
- 25.8: Machining Economics
- 26: Abrasive Machining and Finishing Operations
- 26.1: Introduction
- 26.2: Abrasives and Bonded Abrasives
- 26.3: The Grinding Process
- 26.4: Grinding Operations and Machines
- 26.5: Design Considerations for Grinding
- 26.6: Ultrasonic Machining
- 26.7: Finishing Operations
- 26.8: Deburring Operations
- 26.9: Economics of Abrasive Machining and Finishing Operations
- 27: Advanced Machining Processes
- 27.1: Introduction
- 27.2: Chemical Machining
- 27.3: Electrochemical Machining
- 27.4: Electrochemical Grinding
- 27.5: Electrical-Discharge Machining
- 27.6: Laser-beam Machining
- 27.7: Electron-beam Machining
- 27.8: Water-jet Machining
- 27.9: Abrasive-jet Machining
- 27.10: Hybrid Machining Systems
V: Micromanufacturing and Fabrication of Microelectronic Devices - 28: Fabrication of Microelectronic Devices
- 28.1: Introduction
- 28.2: Clean Rooms
- 28.3: Semiconductors and Silicon
- 28.4: Crystal Growing and Wafer Preparation
- 28.5: Film Deposition
- 28.6: Oxidation
- 28.7: Lithography
- 28.8: Etching
- 28.9: Diffusion and Ion Implantation
- 28.10: Metallization and Testing
- 28.11: Wire Bonding and Packaging
- 28.12: Yield and Reliability
- 28.13: Printed Circuit Boards
- 28.14: Roll-to-Roll Printing of Flexible Electronics
- 28.15: Flexible Hybrid Electronics
- 29: Fabrication of Microelectromechanical Devices and Systems and Nanoscale Manufacturing
- 29.1: Introduction
- 29.2: Micromachining of MEMS Devices
- 29.3: Electroforming-based Processes
- 29.4: Solid Free-form Fabrication of Devices
- 29.5: Mesoscale Manufacturing
- 29.6: Nanoscale Manufacturing
VI: Joining Processes and Equipment - 30: Fusion Welding Processes
- 30.1: Introduction
- 30.2: Oxyfuel–Gas Welding
- 30.3: Arc-welding Processes: Nonconsumable Electrode
- 30.4: Arc-welding Processes: Consumable Electrode
- 30.5: Electrodes for Arc Welding
- 30.6: Electron-beam Welding
- 30.7: Laser-beam Welding
- 30.8: Cutting
- 30.9: The Weld Joint, Quality and Testing
- 30.10: Joint Design and Process Selection
- 31: Solid-state Welding Processes
- 31.1: Introduction
- 31.2: Cold Welding and Roll Bonding
- 31.3: Ultrasonic Welding
- 31.4: Friction Welding
- 31.5: Resistance Welding
- 31.6: Explosion Welding
- 31.7: Diffusion Bonding
- 31.8: Economics of Welding Operations
- 32: Brazing, Soldering, Adhesive-bonding, and Mechanical Fastening Processes
- 32.1: Introduction
- 32.2: Brazing
- 32.3: Soldering
- 32.4: Adhesive Bonding
- 32.5: Mechanical Fastening
- 32.6: Joining Plastics, Ceramics, and Glasses
- 32.7: Economics of Joining Operations
VII: Surface Technology - 33: Surface Roughness and Measurement; Friction, Wear, and Lubrication
- 33.1: Introduction
- 33.2: Surface Structure and Integrity
- 33.3: Surface Texture and Roughness
- 33.4: Friction
- 33.5: Wear
- 33.6: Lubrication
- 33.7: Metalworking Fluids and Their Selection
- 34: Surface Treatments, Coatings, and Cleaning
- 34.1: Introduction
- 34.2: Mechanical Surface Treatments
- 34.3: Mechanical Plating and Cladding
- 34.4: Case Hardening and Hard Facing
- 34.5: Thermal Spraying
- 34.6: Vapor Deposition
- 34.7: Ion Implantation and Diffusion Coating
- 34.8: Laser Treatments
- 34.9: Electroplating, Electroless Plating, and Electroforming
- 34.10: Conversion Coatings
- 34.11: Hot Dipping
- 34.12: Porcelain Enameling; Ceramic and Organic Coatings
- 34.13: Diamond Coating and Diamondlike Carbon
- 34.14: Surface Texturing
- 34.15: Painting
- 34.16: Cleaning of Surfaces
VIII: Engineering Metrology, Instrumentation, and Quality Assurance - 35: Engineering Metrology and Instrumentation
- 35.1: Introduction
- 35.2: Measurement Standards
- 35.3: Geometric Features of Parts: Analog and Digital Measurements
- 35.4: Traditional Measuring Methods and Instruments
- 35.5: Modern Measuring Instruments and Machines
- 35.6: Automated Measurement
- 35.7: General Characteristics and Selection of Measuring Instruments
- 35.8: Geometric Dimensioning and Tolerancing
- 36: Quality Assurance, Testing, and Inspection
- 36.1: Introduction
- 36.2: Product Quality
- 36.3: Quality Assurance
- 36.4: Total Quality Management
- 36.5: Taguchi Methods
- 36.6: The ISO and QS Standards
- 36.7: Statistical Methods of Quality Control
- 36.8: Statistical Process Control
- 36.9: Reliability of Products and Processes
- 36.10: Nondestructive Testing
- 36.11: Destructive Testing
- 36.12: Automated Inspection
IX: Manufacturing in a Competitive Environment - 37: Automation of Manufacturing Processes and Operations
- 37.1: Introduction
- 37.2: Automation
- 37.3: Numerical Control
- 37.4: Adaptive Control
- 37.5: Material Handling and Movement
- 37.6: Industrial Robots
- 37.7: Sensor Technology
- 37.8: Flexible Fixturing
- 37.9: Assembly Systems
- 37.10: Design Considerations for Fixturing, Assembly, Disassembly, and Servicing
- 37.11: Economic Considerations
- 38: Computer-aided Manufacturing
- 38.1: Introduction
- 38.2: Manufacturing Systems
- 38.3: Computer-integrated Manufacturing
- 38.4: Computer-aided Design and Engineering
- 38.5: Computer-aided Manufacturing
- 38.6: Computer-aided Process Planning
- 38.7: Computer Simulation of Manufacturing Processes and Systems
- 38.8: Group Technology
- 39: Computer-integrated Manufacturing Systems
- 39.1: Introduction
- 39.2: Cellular Manufacturing
- 39.3: Flexible Manufacturing Systems
- 39.4: Mass Customization
- 39.5: Holonic Manufacturing
- 39.6: Just-in-time Production
- 39.7: Lean Manufacturing
- 39.8: Communications Networks in Manufacturing
- 39.9: Artificial Intelligence and Machine Learning
- 39.10: Economic Considerations
- 40: Product Design and Manufacturing in a Competitive Environment
- 40.1: Introduction
- 40.2: Product Design
- 40.3: Product Quality
- 40.4: Decarbonization and Sustainable Manufacturing
- 40.5: Energy Consumption in Manufacturing
- 40.6: Material Selection for Products
- 40.7: Material Substitution
- 40.8: Manufacturing Process Capabilities
- 40.9: Process Selection
- 40.10: Manufacturing Costs and Cost Reduction
Index
About the Author :
About our authors Serope Kalpakjian is professor emeritus of Mechanical and Materials Engineering at the Illinois Institute of Technology. He is the author of Mechanical Processing of Materials and co-author of Lubricants and Lubrication in Metalworking Operations (with E.S. Nachtman); the first editions of those textbooks have received the M. Eugene Merchant Manufacturing Textbook Award. He has conducted research in various areas of manufacturing, is the author of numerous technical papers and articles in handbooks and encyclopedias, and has edited a number of conference proceedings. He also has been editor and co-editor of several technical journals and has served on various editorial boards, including the Encyclopedia Americana.
Among various awards, Professor Kalpakjian has received the Forging Industry Educational and Research Foundation Best Paper Award, the Excellence in Teaching Award from IIT, the ASME Centennial Medallion, the International Education Award from SME, A Person of the Millennium Award from lIT, the Albert Easton White Outstanding Teacher Award from ASM International, and the 2016 SME Gold Medal Award. For 2001, Outstanding Young Manufacturing Engineer Award of SME was named after him. Professor Kalpakjian is a Life Fellow ASME, Fellow SME, Fellow and Life Member ASM International, Fellow Emeritus International Academy for Production Engineering (CIRP), and is a founding member and past president of NAMRI. He is a graduate of Robert College (High Honor, Istanbul), Harvard University, and the Massachusetts Institute of Technology.
Steven R. Schmid is the Belk-Woodward Distinguished Professor of Mechanical Engineering at the University of North Carolina - Charlotte, where he teaches and conducts research in the general areas of manufacturing, machine design and tribology. He previously spent almost 30 years on the faculty at the University of Notre Dame. He received his B.S. degree from Illinois Institute of Technology (with Honors) and Master's and Ph.D. from Northwestern University, all in mechanical engineering. He has received numerous awards, including the David Dornfeld Manufacturing Innovation Award and John T. Parsons Awards from SME, the Newkirk Award from ASME, the Kaneb Center Teaching Award (3 times), and the Ruth and Joel Spira Award for Excellence in Teaching. He received the SME Gold Medal in 2022 and a lifetime achievement award from the Spanish manufacturing organization MESIC.
Professor Schmid served as President of the North American Manufacturing Research Institution (NAMRI, 2015-2016) and was appointed the first Academic Fellow at the Advanced Manufacturing National Program Office, U.S. Department of Commerce, where he helped design the Manufacturing USA program. From 2016 to 2018, he served as the Program Director of the Manufacturing Machines and Equipment program and Head of the Advanced Manufacturing Cluster at the National Science Foundation. Dr. Schmid is the author of over 140 technical papers, and has co-authored Fundamentals of Machine Elements, Fundamentals of Fluid Film Lubrication, Schey's Tribology in Metalworking, Manufacturing Processes for Engineering Materials, and Manufacturing Engineering and Technology. He is a Fellow of the American Society of Mechanical Engineers and the Society of Manufacturing Engineers.
