Preface xxiiiAbout the Authors xxviiGeneral Introduction 1I.1 What is Manufacturing? 1I.2 Product Design and Concurrent Engineering 6I.3 Design for Manufacture, Assembly, Disassembly, and Service 10I.4 Green Design and Manufacturing 11I.5 Selection of Materials 13I.6 Selection of Manufacturing Processes 16I.7 Computer-integrated Manufacturing 25I.8 Quality Assurance and Total Quality Management 28I.9 Lean Production and Agile Manufacturing 30I.10 Manufacturing Costs and Global Competition 31I.11 Trends in Manufacturing 32 Part I: Fundamentals of Materials: Behavior and Manufacturing Properties 351 The Structure of Metals 381.1 Introduction 381.2 Types of Atomic Bonds 391.3 The Crystal Structure of Metals 401.4 Deformation and Strength of Single Crystals 421.5 Grains and Grain Boundaries 451.6 Plastic Deformation of Polycrystalline Metals 481.7 Recovery, Recrystallization, and Grain Growth 491.8 Cold, Warm, and Hot Working 50Summary 51 Key Terms 51 Bibliography 52Review Questions 52 Qualitative Problems 52Quantitative Problems 53 Synthesis, Design, and Projects 54 2 Mechanical Behavior, Testing, and Manufacturing Properties of Materials 552.1 Introduction 552.2 Tension 562.3 Compression 652.4 Torsion 662.5 Bending (Flexure) 672.6 Hardness 672.7 Fatigue 732.8 Creep 742.9 Impact 742.10 Failure and Fracture of Materials 752.11 Residual Stresses 802.12 Work, Heat, and Temperature 81Summary 82 Key Terms 83 Bibliography 83Review Questions 84 Qualitative Problems 84Quantitative Problems 85 Synthesis, Design, and Projects 86 3 Physical Properties of Materials 883.1 Introduction 883.2 Density 893.3 Melting Point 923.4 Specific Heat 923.5 Thermal Conductivity 933.6 Thermal Expansion 933.7 Electrical, Magnetic, and Optical Properties 943.8 Corrosion Resistance 95Summary 97 Key Terms 98 Bibliography 98Review Questions 98 Qualitative Problems 98Quantitative Problems 99 Synthesis, Design, and Projects 99 4 Metal Alloys: Their Structure and Strengthening by Heat Treatment 1014.1 Introduction 1014.2 Structure of Alloys 1024.3 Phase Diagrams 1044.4 The Iron-Carbon System 1074.5 The Iron-Iron-carbide Phase Diagram and the Development of Microstructures in Steels 1084.6 Cast Irons 1094.7 Heat Treatment of Ferrous Alloys 1114.8 Hardenability of Ferrous Alloys 1134.9 Heat Treatment of Nonferrous Alloys and Stainless Steels 1174.10 Case Hardening 1194.11 Annealing 1214.12 Heat-treating Furnaces and Equipment 1234.13 Design Considerations for Heat Treating 124Review Questions 126 Qualitative Problems 127Quantitative Problems 127 Synthesis, Design, and Projects 127 5 Ferrous Metals and Alloys: Production, General Properties, and Applications 1285.1 Introduction 1285.2 Production of Iron and Steel 1295.3 Casting of Ingots 1325.4 Continuous Casting 1335.5 Carbon and Alloy Steels 1355.6 Stainless Steels 1425.7 Tool and Die Steels 144Summary 145 Key Terms 146 Bibliography 147Review Questions 147 Qualitative Problems 147Quantitative Problems 148 Synthesis, Design, and Projects 148 6 Nonferrous Metals and Alloys: Production, General Properties, and Applications 1506.1 Introduction 1506.2 Aluminum and Aluminum Alloys 1516.3 Magnesium and Magnesium Alloys 1556.4 Copper and Copper Alloys 1566.5 Nickel and Nickel Alloys 1586.6 Superalloys 1596.7 Titanium and Titanium Alloys 1606.8 Refractory Metals and Alloys 1616.9 Beryllium 1626.10 Zirconium 1626.11 Low-melting Alloys 1626.12 Precious Metals 1646.13 Shape-memory Alloys (Smart Materials) 1646.14 Amorphous Alloys (Metallic Glasses) 1656.15 Metal Foams 165Summary 166 Key Terms 166 Bibliography 166Review Questions 167 Qualitative Problems 167Quantitative Problems 167 Synthesis, Design, and Projects 168 7 Polymers: Structure, General Properties, and Applications 1697.1 Introduction 1697.2 The Structure of Polymers 1717.3 Thermoplastics 1787.4 Thermosetting Plastics 1817.5 Additives in Plastics 1827.6 General Properties and Applications of Thermoplastics 1837.7 General Properties and Applications of Thermosetting Plastics 1867.8 Biodegradable Plastics 1877.9 Elastomers (Rubbers) 188Summary 189 Key Terms 190 Bibliography 190Review Questions 191 Qualitative Problems 191Quantitative Problems 192 Synthesis, Design, and Projects 193 8 Ceramics, Glass, Graphite, Diamond, and Nanomaterials: Structure, General Properties, and Applications 1948.1 Introduction 1948.2 The Structure of Ceramics 1958.3 General Properties and Applications of Ceramics 2008.4 Glasses 2048.5 Glass Ceramics 2068.6 Graphite 2078.7 Diamond 2098.8 Nanomaterials 210Summary 211 Key Terms 212 Bibliography 212Review Questions 212 Qualitative Problems 213Quantitative Problems 213 Synthesis, Design, and Projects 213 9 Composite Materials: Structure, General Properties, and Applications 2159.1 Introduction 2159.2 The Structure of Reinforced Plastics 2169.3 Properties of Reinforced Plastics 2219.4 Applications of Reinforced Plastics 2249.5 Metal-matrix Composites 2269.6 Ceramic-matrix Composites 2289.7 Other Composites 229Summary 230 Key Terms 230 Bibliography 230Review Questions 231 Qualitative Problems 231Quantitative Problems 232 Synthesis, Design, and Projects 232 Part II: Metal-casting Processes and Equipment 23510 Fundamentals of Metal Casting 23710.1 Introduction 23710.2 Solidification of Metals 23810.3 Fluid Flow 24310.4 Fluidity of Molten Metal 24610.5 Heat Transfer 24710.6 Defects 249Summary 252 Key Terms 252 Bibliography 253Review Questions 253 Qualitative Problems 253Quantitative Problems 254 Synthesis, Design, and Projects 255 11 Metal-casting Processes and Equipment 25611.1 Introduction 25611.2 Expendable-mold, Permanent-pattern Casting Processes 26011.3 Expendable-mold, Expendable-pattern Casting Processes 26911.4 Permanent-mold Casting Processes 27611.5 Casting Techniques for Single-crystal Components 28411.6 Rapid Solidification 28611.7 Inspection of Castings 28711.8 Melting Practice and Furnaces 28711.9 Foundries and Foundry Automation 289Summary 289 Key Terms 290 Bibliography 290Review Questions 290 Qualitative Problems 291Quantitative Problems 291 Synthesis, Design, and Projects 292 12 Metal Casting: Design, Materials, and Economics 29412.1 Introduction 29412.2 Design Considerations in Casting 29412.3 Casting Alloys 30312.4 Economics of Casting 308Summary 309 Key Terms 309 Bibliography 309Review Questions 310 Qualitative Problems 310Quantitative Problems 310 Synthesis, Design, and Projects 311 Part III: Forming and Shaping Processes and Equipment 31313 Metal-rolling Processes and Equipment 31613.1 Introduction 31613.2 The Flat-rolling Process 31813.3 Flat-rolling Practice 32313.4 Rolling Mills 32613.5 Various Rolling Processes and Mills 328Summary 333 Key Terms 333 Bibliography 334Review Questions 334 Qualitative Problems 334Quantitative Problems 335 Synthesis, Design, and Projects 336 14 Metal-forging Processes and Equipment 33714.1 Introduction 33714.2 Open-die Forging 33914.3 Impression-die and Closed-die Forging 34214.4 Various Forging Operations 34514.5 Forgeability of Metals; Forging Defects 34914.6 Die Design, Die Materials, and Lubrication 35114.7 Die-manufacturing Methods and Die Failure 35414.8 Forging Machines 35514.9 Economics of Forging 358Summary 360 Key Terms 361 Bibliography 361Review Questions 362 Qualitative Problems 362Quantitative Problems 362 Synthesis, Design, and Projects 363 15 Metal Extrusion and Drawing Processes and Equipment 36415.1 Introduction 36415.2 The Extrusion Process 36615.3 Hot Extrusion 36815.4 Cold Extrusion 37215.5 Extrusion Defects 37415.6 Design Considerations 37615.7 Extrusion Equipment 37615.8 The Drawing Process 37715.9 Drawing Practice 37915.10 Drawing Defects and Residual Stresses 38215.11 Drawing Equipment 382Summary 384 Key Terms 383 Bibliography 384Review Questions 384 Qualitative Problems 384Quantitative Problems 385 Synthesis, Design, and Projects 385 16 Sheet-metal Forming Processes and Equipment 38616.1 Introduction 38616.2 Shearing 38716.3 Sheet-metal Characteristics and Formability 39716.4 Formability Tests for Sheet Metals 39916.5 Bending Sheets, Plates, and Tubes 40216.6 Miscellaneous Bending and Related Forming Operations 40616.7 Deep Drawing 41116.8 Rubber Forming and Hydroforming 41916.9 Spinning 42316.10 Superplastic Forming 42616.11 Hot Stamping 42716.12 Specialized Forming Processes 42816.13 Manufacturing of Metal Honeycomb Structures 43316.14 Design Considerations in Sheet-metal Forming 43416.15 Equipment for Sheet-metal Forming 43716.16 Economics of Sheet-forming Operations 438Summary 439 Key Terms 440 Bibliography 440Review Questions 440 Qualitative Problems 441Quantitative Problems 441 Synthesis, Design, and Projects 442 17 Powder Metal Processes and Equipment 44417.1 Introduction 44417.2 Production of Metal Powders 44517.3 Compaction of Metal Powders 45017.4 Sintering 46117.5 Secondary and Finishing Operations 46417.6 Design Considerations 46617.7 Economics of Powder Metallurgy 469Summary 471 Key Terms 471 Bibliography 471Review Questions 472 Qualitative Problems 472Quantitative Problems 473 Synthesis, Design, and Projects 473 18 Ceramics, Glasses, and Superconductors: Processing and Equipment 47518.1 Introduction 47518.2 Shaping Ceramics 47618.3 Forming and Shaping of Glass 48318.4 Techniques for Strengthening and Annealing Glass 48618.5 Design Considerations for Ceramics and Glasses 48918.6 Processing of Superconductors 489Summary 491 Key Terms 491 Bibliography 492Review Questions 492 Qualitative Problems 492Quantitative Problems 493 Synthesis, Design, and Projects 493 19 Plastics and Composite Materials: Forming and Shaping 49419.1 Introduction 49419.2 Extrusion 49519.3 Injection Molding 50219.4 Blow Molding 50919.5 Rotational Molding 50919.6 Thermoforming 51119.7 Compression Molding 51219.8 Transfer Molding 51319.9 Casting 51419.10 Foam Molding 51519.11 Cold Forming and Solid-phase Forming 51619.12 Processing Elastomers 51719.13 Processing Polymer-matrix Composites 51819.14 Processing Metal-matrix and Ceramic-matrix Composites 52719.15 Design Considerations 52819.16 Economics of Processing Plastics and Composite Materials 530Summary 531 Key Terms 531 Bibliography 532Review Questions 532 Qualitative Problems 532Quantitative Problems 533 Synthesis, Design, and Projects 533 20 Rapid-prototyping Processes and Operations 53520.1 Introduction 53520.2 Subtractive Processes 53820.3 Additive Processes 54020.4 Virtual Prototyping 55120.5 Self-replicating Machines 55220.6 Direct Manufacturing and Rapid Tooling 553Summary 560 Key Terms 560 Bibliography 560Review Questions 561 Qualitative Problems 561Quantitative Problems 562 Synthesis, Design, and Projects 562 Part IV: Machining Processes and Machine Tools 56321 Fundamentals of Machining 56621.1 Introduction 56621.2 Mechanics of Cutting 56721.3 Cutting Forces and Power 57721.4 Temperatures in Cutting 58021.5 Tool Life: Wear and Failure 58221.6 Surface Finish and Integrity 58921.7 Machinability 591Summary 595 Key Terms 596 Bibliography 596Review Questions 596 Qualitative Problems 597Quantitative Problems 598 Synthesis, Design, and Projects 599 22 Cutting-tool Materials and Cutting Fluids 60022.1 Introduction 60022.2 High-speed Steels 60422.3 Cast-cobalt Alloys 60522.4 Carbides 60522.5 Coated Tools 60922.6 Alumina-based Ceramics 61222.7 Cubic Boron Nitride 61322.8 Silicon-nitride-based Ceramics 61422.9 Diamond 61422.10 Whisker-reinforced Materials and Nanomaterials 61522.11 Tool Costs and Reconditioning of Tools 61622.12 Cutting Fluids 616Summary 622 Key Terms 622 Bibliography 622Review Questions 623 Qualitative Problems 623Quantitative Problems 624 Synthesis, Design, and Projects 624 23 Machining Processes: Turning and Hole Making 62523.1 Introduction 62523.2 The Turning Process 62823.3 Lathes and Lathe Operations 63623.4 Boring and Boring Machines 65123.5 Drilling, Drills, and Drilling Machines 65223.6 Reaming and Reamers 66123.7 Tapping and Taps 662Summary 664 Key Terms 665 Bibliography 665Review Questions 665 Qualitative Problems 666Quantitative Problems 666 Synthesis, Design, and Projects 667 24 Machining Processes: Milling, Broaching, Sawing, Filing, and Gear Manufacturing 66824.1 Introduction 66824.2 Milling and Milling Machines 66924.3 Planing and Shaping 68424.4 Broaching and Broaching Machines 68424.5 Sawing 68824.6 Filing 69224.7 Gear Manufacturing by Machining 692Summary 699 Key Terms 700 Bibliography 700Review Questions 700 Qualitative Problems 700Quantitative Problems 701 Synthesis, Design, and Projects 702 25 Machining Centers, Machine-Tool Structures, and Machining Economics 70325.1 Introduction 70325.2 Machining Centers 70325.3 Machine-tool Structures 71225.4 Vibration and Chatter in Machining Operations 71625.5 High-speed Machining 71925.6 Hard Machining 72025.7 Ultraprecision Machining 72125.8 Machining Economics 722Summary 726 Key Terms 726 Bibliography 727Review Questions 727 Qualitative Problems 727Quantitative Problems 728 Synthesis, Design, and Projects 728 26 Abrasive Machining and Finishing Operations 72926.1 Introduction 72926.2 Abrasives and Bonded Abrasives 73126.3 The Grinding Process 73726.4 Grinding Operations and Machines 74626.5 Design Considerations for Grinding 75526.6 Ultrasonic Machining 75526.7 Finishing Operations 75626.8 Deburring Operations 76126.9 Economics of Abrasive Machining and Finishing Operations 764Summary 765 Key Terms 765 Bibliography 766Review Questions 766 Qualitative Problems 767Quantitative Problems 767 Synthesis, Design, and Projects 768 27 Advanced Machining Processes and Equipment 76927.1 Introduction 76927.2 Chemical Machining 77027.3 Electrochemical Machining 77527.4 Electrochemical Grinding 77927.5 Electrical-discharge Machining 78027.6 Laser-beam Machining 78427.7 Electron-beam Machining 78727.8 Water-jet Machining 78827.9 Abrasive-jet Machining 79027.10 Hybrid Machining Systems 79027.11 Economics of Advanced Machining Processes 791Summary 794 Key Terms 794 Bibliography 795Review Questions 795 Quantitative Problems 795Qualitative Problems 796 Synthesis, Design, and Projects 796 Part V: Micromanufacturing and Fabrication of Microelectronic Devices 79728 Fabrication of Microelectronic Devices 80028.1 Introduction 80028.2 Clean Rooms 80328.3 Semiconductors and Silicon 80428.4 Crystal Growing and Wafer Preparation 80528.5 Film Deposition 80728.6 Oxidation 80928.7 Lithography 81028.8 Etching 81828.9 Diffusion and Ion Implantation 82528.10 Metallization and Testing 82728.11 Wire Bonding and Packaging 83028.12 Yield and Reliability 83528.13 Printed Circuit Boards 835Summary 837 Key Terms 838 Bibliography 838Review Questions 838 Qualitative Problems 839Quantitative Problems 839 Synthesis, Design, and Projects 840 29 Fabrication of Microelectromechanical Devices and Systems and Nanoscale Manufacturing 84129.1 Introduction 84129.2 Micromachining of MEMS Devices 84329.3 Electroforming-based Processes 85429.4 Solid Free-form Fabrication of Devices 86129.5 Nanoscale Manufacturing 866Summary 869 Key Terms 869 Bibliography 869Review Questions 870 Qualitative Problems 870Quantitative Problems 870 Synthesis, Design, and Projects 871 Part VI: Joining Processes and Equipment 87330 Fusion Welding Processes 87730.1 Introduction 87730.2 Oxyfuel-gas Welding 87730.3 Arc-welding Processes: Nonconsumable Electrode 88230.4 Arc-welding Processes: Consumable Electrode 88530.5 Electrodes for Arc Welding 89030.6 Electron-beam Welding 89230.7 Laser-beam Welding 89330.8 Cutting 89430.9 The Weld Joint, Quality, and Testing 89630.10 Joint Design and Process Selection 905Summary 908 Key Terms 909 Bibliography 909Review Questions 909 Qualitative Problems 910Quantitative Problems 910 Synthesis, Design, and Projects 911 31 Solid-State Welding Processes 91231.1 Introduction 91231.2 Cold Welding and Roll Bonding 91331.3 Ultrasonic Welding 91431.4 Friction Welding 91531.5 Resistance Welding 91731.6 Explosion Welding 92531.7 Diffusion Bonding 92631.8 Economics of Welding Operations 928Summary 930 Key Terms 930 Bibliography 931Review Questions 931 Qualitative Problems 931Quantitative Problems 932 Synthesis, Design, and Projects 932 32 Brazing, Soldering, Adhesive-bonding, and Mechanical Fastening Processes 93432.1 Introduction 93432.2 Brazing 93532.3 Soldering 93932.4 Adhesive-bonding 94332.5 Mechanical Fastening 94932.6 Joining Plastics, Ceramics, and Glasses 95332.7 Economics of Joining Operations 957Summary 958 Key Terms 958 Bibliography 959Review Questions 959 Qualitative Problems 959Quantitative Problems 960 Synthesis, Design, and Projects 960 Part VII: Surface Technology 96133 Surface Roughness and Measurement; Friction, Wear, and Lubrication 96333.1 Introduction 96333.2 Surface Structure and Integrity 96433.3 Surface Texture and Roughness 96633.4 Friction 96933.5 Wear 97333.6 Lubrication 97633.7 Metalworking Fluids and Their Selection 978Summary 981 Key Terms 982 Bibliography 982Review Questions 983 Qualitative Problems 983Quantitative Problems 984 Synthesis, Design, and Projects 984 34 Surface Treatments, Coatings, and Cleaning 98534.1 Introduction 98534.2 Mechanical Surface Treatments 98634.3 Mechanical Plating and Cladding 98734.4 Case Hardening and Hard Facing 98834.5 Thermal Spraying 98834.6 Vapor Deposition 98934.7 Ion Implantation and Diffusion Coating 99334.8 Laser Treatments 99334.9 Electroplating, Electroless Plating, and Electroforming 99434.10 Conversion Coatings 99834.11 Hot Dipping 99834.12 Porcelain Enameling; Ceramic and Organic Coatings 99934.13 Diamond Coating and Diamondlike Carbon 100034.14 Surface Texturing 100134.15 Painting 100134.16 Cleaning of Surfaces 1002Summary 1004 Key Terms 1004 Bibliography 1004Review Questions 1005 Qualitative Problems 1005Quantitative Problems 1005 Synthesis, Design, and Projects 1005 Part VIII: Engineering Metrology, Instrumentation, and Quality Assurance 100735 Surface Treatments, Coatings, and Cleaning 100835.1 Introduction 100835.2 Measurement Standards 100835.3 Geometric Features of Parts: Analog and Digital Measurements 101035.4 Traditional Measuring Methods and Instruments 101035.5 Modern Measuring Instruments and Machines 101735.6 Automated Measurement 102035.7 General Characteristics and Selection of Measuring Instruments 102135.8 Geometric Dimensioning and Tolerancing 1021Summary 1027 Key Terms 1027 Bibliography 1027Review Questions 1027 Qualitative Problems 1028Quantitative Problems 1028 Synthesis, Design, and Projects 1029 36 Quality Assurance, Testing, and Inspection 103036.1 Introduction 103036.2 Product Quality 103136.3 Quality Assurance 103136.4 Total Quality Management 103236.5 Taguchi Methods 103436.6 The ISO and QS Standards 103836.7 Statistical Methods of Quality Control 103936.8 Statistical Process Control 104236.9 Reliability of Products and Processes 104836.10 Nondestructive Testing 104836.11 Destructive Testing 105236.12 Automated Inspection 1052Summary 1053 Key Terms 1054 Bibliography 1054Review Questions 1054 Qualitative Problems 1055Quantitative Problems 1055 Synthesis, Design, and Projects 1056 Part IX: Manufacturing in a Competitive Environment 105737 Automation of Manufacturing Processes and Operations 105937.1 Introduction 105937.2 Automation 106137.3 Numerical Control 106837.4 Adaptive Control 107437.5 Material Handling and Movement 107737.6 Industrial Robots 107837.7 Sensor Technology 108537.8 Flexible Fixturing 108937.9 Assembly Systems 109037.10 Design Considerations for Fixturing, Assembly, Disassembly, and Servicing 109437.11 Economic Considerations 1096Summary 1097 Key Terms 1097 Bibliography 1098Review Questions 1098 Qualitative Problems 1099Quantitative Problems 1099 Synthesis, Design, and Projects 1099 38 Computer-aided Manufacturing 110138.1 Introduction 110138.2 Manufacturing Systems 110238.3 Computer-integrated Manufacturing 110238.4 Computer-aided Design and Engineering 110538.5 Computer-aided Manufacturing 111138.6 Computer-aided Process Planning 111238.7 Computer Simulation of Manufacturing Processes and Systems 111438.8 Group Technology 1116Summary 1123 Key Terms 1124 Bibliography 1124Review Questions 1124 Qualitative Problems 1124Synthesis, Design, and Projects 1125 39 Computer-integrated Manufacturing Systems 112639.1 Introduction 112639.2 Cellular Manufacturing 112739.3 Flexible Manufacturing Systems 112839.4 Holonic Manufacturing 113139.5 Just-in-time Production 113339.6 Lean Manufacturing 113439.7 Communications Networks in Manufacturing 113639.8 Artificial Intelligence 113739.9 Economic Considerations 1140Summary 1140 Key Terms 1141 Bibliography 1141Review Questions 1141 Qualitative Problems 1142Synthesis, Design, and Projects 1142 40 Product Design and Manufacturing in a Competitive Environment 114340.1 Introduction 114340.2 Product Design 114440.3 Product Quality 114740.4 Life-cycle Assessment and Sustainable Manufacturing 114740.5 Energy Consumption in Manufacturing 114940.6 Material Selection for Products 115140.7 Material Substitution 115340.8 Manufacturing Process Capabilities 115540.9 Process Selection 115740.10 Manufacturing Costs and Cost Reduction 1160Summary 1165 Key Terms 1165 Bibliography 1165Review Questions 1166 Qualitative Problems 1166Synthesis, Design, and Projects 1167Index