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ISBN 10: 1119633729
ISBN 13: 9781119633723
Author: Black; Ronald
Guiding engineering and technology students for over five decades, DeGarmo’s Materials and Processes in Manufacturing provides a comprehensive introduction to manufacturing materials, systems, and processes. Coverage of materials focuses on properties and behavior, favoring a practical approach over complex mathematics; analytical equations and mathematical models are only presented when they strengthen comprehension and provide clarity. Material production processes are examined in the context of practical application to promote efficient understanding of basic principles, and broad coverage of manufacturing processes illustrates the mechanisms of each while exploring their respective advantages and limitations.
Aiming for both accessibility and completeness, this text offers introductory students a comprehensive guide to material behavior and selection, measurement and inspection, machining, fabrication, molding, fastening, and other important processes using plastics, ceramics, composites, and ferrous and nonferrous metals and alloys. This extensive overview of the field gives students a solid foundation for advanced study in any area of engineering, manufacturing, and technology.
Table of contents:
Chapter 1: Introduction to DeGarmo’s Materials and Processes in Manufacturing
Review Questions
Problems
Key words
CASE STUDY Famous Manufacturing Engineers
Readings
1.1 Materials, Manufacturing, and the Standard of Living
1.2 Manufacturing and Production Systems
Chapter 2: Properties of Materials
Review Questions
Problems
Key words
CASE STUDY Separation of Mixed Materials
Readings
2.1 Introduction
2.2 Static Properties
2.3 Dynamic Properties
2.4 Temperature Effects (Both High and Low)
2.5 Machinability, Formability, and Weldability
2.6 Fracture Toughness and the Fracture Mechanics Approach
2.7 Physical Properties
2.8 Testing Standards and Testing Concerns
Chapter 3: Nature of Materials
Review Questions
Problems
Key words
Readings
3.1 Structure—Property—Processing—Performance Relationships
3.2 The Structure of Atoms
3.3 Atomic Bonding
3.4 Secondary Bonds
3.5 Atom Arrangements in Materials
3.6 Crystal Structures
3.7 Development of a Grain Structure
3.8 Elastic Deformation
3.9 Plastic Deformation
3.10 Dislocation Theory of Slippage
3.11 Strain Hardening or Work Hardening
3.12 Plastic Deformation in Polycrystalline Material
3.13 Grain Shape and Anisotropic Properties
3.14 Fracture
3.15 Cold Working, Recrystallization, and Hot Working
3.16 Grain Growth
3.17 Alloys and Alloy Types
3.18 Atomic Structure and Electrical Properties
Chapter 4: Equilibrium Phase Diagrams and the Iron–Carbon System
Review Questions
Problems
Key words
Case Studies
Fishhooks
The Blacksmith Anvils
Readings
4.1 Introduction
4.2 Phases
4.3 Equilibrium Phase Diagrams
4.4 Iron–Carbon Equilibrium Diagram
4.5 Steels and the Simplified Iron–Carbon Diagram
4.6 Cast Irons
Chapter 5: Heat Treatment
Review Questions
Problems
Key words
Case Studies
A Carpenter’s Claw Hammer
A Flying Chip from a Sledgehammer
Readings
5.1 Introduction
5.2 Processing Heat Treatments
5.3 Heat Treatments Used to Increase Strength
5.4 Strengthening Heat Treatments for Nonferrous Metals
5.5 Strengthening Heat Treatments for Steel
5.6 Surface Hardening of Steel
5.7 Furnaces
5.8 Heat Treatment and Energy
Chapter 6: Ferrous Metals and Alloys
Review Questions
Problems
Key words
CASE STUDY The Paper Clip
Readings
6.1 Introduction to History‐Dependent Materials
6.2 Ferrous Metals
6.3 Iron
6.4 Steel
6.5 Stainless Steels
6.6 Tool Steels
6.7 Cast Irons
6.8 Cast Steels
6.9 The Role of Processing on Cast Properties
Chapter 7: Nonferrous Metals and Alloys
Review Questions
Problems
Key words
Case Studies
Hip Replacement Prosthetics
Replacement US Coinage
Readings
7.1 Introduction
7.2 Copper and Copper Alloys
7.3 Aluminum and Aluminum Alloys
7.4 Magnesium and Magnesium Alloys
7.5 Zinc and Zinc Alloys
7.6 Titanium and Titanium Alloys
7.7 Nickel‐Based Alloys
7.8 Superalloys, Refractory Metals, and Other Materials Designed for High‐Temperature Service
7.9 Lead and Tin and Their Alloys
7.10 Some Lesser‐Known Metals and Alloys
7.11 Metallic Glasses
7.12 Graphite
7.13 Materials for Specific Applications
7.14 High Entropy Alloys
Chapter 8: Nonmetallic Materials: Plastics,* Elastomers,** Ceramics, and Composites
Review Questions
Problems
Key words
Case Studies
Lightweight Armor and Protective Helmets
Two‐Wheel Dolly Handles
Readings
8.1 Introduction
8.2 Plastics
8.3 Elastomers
8.4 Ceramics
8.5 Composite Materials
Chapter 9: Material Selection
Review Questions
Problems
Key words
CASE STUDY Material Selection
Readings
9.1 Introduction
9.2 Material Selection and Manufacturing Processes
9.3 The Design Process
9.4 Approaches to Material Selection
9.5 Additional Factors to Consider
9.6 Consideration of the Manufacturing Process
9.7 Ultimate Objective
9.8 Materials Substitution
9.9 Effect of Product Liability on Materials Selection
9.10 Aids to Material Selection
Chapter 10: Measurement and Inspection
Review Questions
Problems
Key words
CASE STUDY Measuring an Angle
Readings
10.1 Introduction
10.2 Standards of Measurement
10.3 Allowance and Tolerance
10.4 Inspection Methods for Measurement
10.5 Measuring Instruments
10.6 Vision Systems
10.7 Coordinate Measuring Machines
10.8 Angle‐Measuring Instruments
10.9 Gages for Attributes Measuring
Chapter 11: Nondestructive Examination (NDE) / Nondestructive Testing (NDT)
Review Questions
Problems
Key words
CASE STUDY Portable Failure Analysis Kit
Readings
11.1 Destructive vs. Nondestructive Testing
11.2 Visual Inspection
11.3 Liquid Penetrant Inspection
11.4 Magnetic Particle Inspection
11.5 Ultrasonic Inspection
11.6 Radiography
11.7 Eddy‐Current Testing
11.8 Acoustic Emission Monitoring
11.9 Other Methods of Nondestructive Testing and Inspection
11.10 Dormant vs. Critical Flaws
11.11 Current and Future Trends
Chapter 12: Process Capability and Quality Control
Review Questions
Problems
Key words
CASE STUDY QC Chart Blunders
Readings
12.1 Introduction
12.2 Determining Process Capability
12.3 Introduction to Statistical Quality Control
12.4 Sampling Errors
12.5 Gage Capability
12.6 Just in Time/Total Quality Control
12.7 Six Sigma
12.8 Summary
Chapter 13: Fundamentals of Casting
Review Questions
Problems
Key words
CASE STUDY The Cast Oil‐Field Fitting
Readings
13.1 Introduction to Materials Processing
13.2 Introduction to Casting
13.3 Casting Terminology
13.4 The Solidification Process
13.5 Patterns
13.6 Design Considerations in Castings
13.7 The Casting Industry
Chapter 14: Expendable‐Mold Casting Processes
Review Questions
Problems
Key words
Case Studies
Trailer Hitch Component
Moveable and Fixed Jaw Pieces for a Heavy‐duty Bench Vise
Readings
14.1 Introduction
14.2 Sand Casting
14.3 Cores and Core Making
14.4 Other Expendable‐Mold Processes with Multiple‐Use Patterns
14.5 Expendable‐Mold Processes Using Single‐Use Patterns
14.6 Shakeout, Cleaning, and Finishing
14.7 Summary
Chapter 15: Multiple‐Use‐Mold Casting Processes
Review Questions
Problems
Key words
CASE STUDY Baseplate for a Household Steam Iron
Readings
15.1 Introduction
15.2 Permanent‐Mold Casting
15.3 Die Casting
15.4 Squeeze Casting and Semisolid Casting
15.5 Centrifugal Casting
15.6 Continuous Casting
15.7 Melting
15.8 Pouring Practice
15.9 Cleaning, Finishing, Heat Treating, and Inspection
15.10 Automation in Foundry Operations
15.11 Process Selection
Chapter 16: Powder Metallurgy (Particulate Processing)
Review Questions
Problems
Key words
Case Studies
Steering Gear for a Riding Lawn Mower/Garden Tractor
Impeller for an Automobile Water Pump
Readings
16.1 Introduction
16.2 The Basic Process
16.3 Powder Manufacture
16.4 Powder Testing and Evaluation
16.5 Powder Mixing and Blending
16.6 Compacting
16.7 Sintering
16.8 Advances in Sintering (Shorter Time, Higher Density, Stronger Products)
16.9 Hot‐Isostatic Pressing
16.10 Other Techniques to Produce High‐Density P/M Products
16.11 Metal Injection Molding (MIM)
16.12 Secondary Operations
16.13 Properties of P/M Products
16.14 Design of Powder Metallurgy Parts
16.15 Powder Metallurgy Products
16.16 Advantages and Disadvantages of Powder Metallurgy
16.17 Process Summary
Chapter 17: Fundamentals of Metal Forming
Review Questions
Problems
Key words
Case Studies
Interior Tub of a Top‐Loading Washing Machine
Repairs to a Damaged Propeller
Readings
17.1 Introduction
17.2 Forming Processes: Independent Variables
17.3 Dependent Variables
17.4 Independent–Dependent Relationships
17.5 Process Modeling
17.6 General Parameters
17.7 Friction, Lubrication, and Wear under Metalworking Conditions
17.8 Temperature Concerns
17.9 Formability
Chapter 18: Bulk‐Forming Processes
Review Questions
Problems
Key words
CASE STUDY Automotive Engine Connecting Rod
Readings
18.1 Introduction
18.2 Classification of Deformation Processes
18.3 Bulk Deformation Processes
18.4 Rolling
18.5 Forging
18.6 Extrusion
18.7 Wire, Rod, and Tube Drawing
18.8 Cold Forming, Cold Forging, and Impact Extrusion
18.9 Piercing
18.10 Other Squeezing Processes
18.11 Surface Improvement by Deformation Processing
Chapter 19: Sheet‐Forming Processes
Review Questions
Problems
Key words
Case Studies
Automotive Body Panels
Fabrication of a One‐Piece Brass Flashlight Case
Metal Food and Beverage Cans
Readings
19.1 Introduction
19.2 Shearing Operations
19.3 Bending
19.4 Drawing and Stretching Processes
19.5 Alternative Methods of Producing Sheet‐Type Products
19.6 Seamed Pipe Manufacture
19.7 Presses
Chapter 20: Fabrication of Plastics, Ceramics, and Composites
Review Questions
Problems
Key words
Case Studies
Automotive and Light Truck Fuel Tanks
Fabrication of Lavatory Washbasins
Readings
20.1 Introduction
20.2 Fabrication of Plastics
20.3 Processing of Rubber and Elastomers
20.4 Processing of Ceramics
20.5 Fabrication of Composite Materials
Chapter 21: Fundamentals of Machining/Orthogonal Machining
Review Questions
Problems
Key words
CASE STUDY Orthogonal Plate Machining Experiment at Auburn University
Readings
21.1 Introduction
21.2 Fundamentals
21.3 Forces and Power in Machining
21.4 Orthogonal Machining (Two Forces)
21.5 Chip Thickness Ratio, rc
21.6 Mechanics of Machining (Statics)
21.7 Shear Strain, γ, and Shear Front Angle, ϕ
21.8 Mechanics of Machining (Dynamics) (Section courtesy of Dr. Elliot Stern)
Summary
Chapter 22: Cutting Tool Materials
Review Questions
Problems
Key words
CASE STUDY Comparing Tool Materials Based on Tool Life
Readings
22.1 Cutting Tool Materials
22.2 Tool Geometry
22.3 Tool‐Coating Processes
22.4 Tool Failure and Tool Life
22.5 Taylor Tool Life
22.6 Cutting Fluids
22.7 Economics of Machining
Chapter 23: Turning and Boring Processes
Review Questions
Problems
Key words
CASE STUDY Estimating the Machining Time for Turning
Readings
23.1 Introduction
23.2 Fundamentals of Turning, Boring, and Facing Turning
23.3 Lathe Design and Terminology
23.4 Cutting Tools for Lathes
23.5 Workholding in Lathes
Chapter 24: Milling
Review Questions
Problems
Key words
CASE STUDY HSS vs. Tungsten Carbide Milling
Readings
24.1 Introduction
24.2 Fundamentals of Milling Processes
24.3 Milling Tools and Cutters
24.4 Machines for Milling
Chapter 25: Drilling and Related Hole‐Making Processes
Review Questions
Problems
Key words
CASE STUDY Bolt‐down Leg on a Casting
Readings
25.1 Introduction
25.2 Fundamentals of the Drilling Process
25.3 Types of Drills
25.4 Tool Holders for Drills
25.5 Workholding for Drilling
25.6 Machine Tools for Drilling
25.7 Cutting Fluids for Drilling
25.8 Counterboring, Countersinking, and Spot Facing
25.9 Reaming
Chapter 26: CNC Processes and Adaptive Control: A(4) and A(5) Levels of Automation
Review Questions
Problems
Key words
Readings
26.1 Introduction
26.2 Basic Principles of Numerical Control
26.3 CNC Part Programming
26.4 Interpolation and Adaptive Control
26.5 Machining Center Features and Trends
26.6 Summary
Chapter 27: Sawing, Broaching, Shaping, and Filing Machining Processes
Review Questions
Problems
Key words
CASE STUDY Three Case Studies on Cost Estimating
Readings
27.1 Introduction
27.2 Introduction to Sawing
27.3 Introduction to Broaching
27.4 Fundamentals of Broaching
27.5 Broaching Machines
27.6 Introduction to Shaping and Planing
27.7 Introduction to Filing
Chapter 28: Abrasive Machining Processes
Review Questions
Problems
Key words
CASE STUDY Process Planning for the MfE
Readings
28.1 Introduction
28.2 Abrasives
28.3 Grinding Wheel Structure and Grade
28.4 Grinding Wheel Identification
28.5 Grinding Machines
28.6 Honing
28.7 Superfinishing
28.8 Free Abrasives
28.9 Design Considerations in Grinding
Chapter 29: Nano and Micro‐Manufacturing Processes
Review Questions
Problems
Key words
Readings
29.1 Introduction
29.2 Lithography
29.3 Micromachining Processes
29.4 Deposition Processes
29.5 How ICs Are Made
29.6 Nano‐ and Micro‐Scale Metrology
Chapter 30: Nontraditional Manufacturing Processes
Review Questions
Key words
CASE STUDY Vented Cap Screws
Readings
30.1 Introduction
30.2 Chemical Machining Processes
30.3 Electrochemical Machining Processes
30.4 Electrical Discharge Machining
Chapter 31: Thread and Gear Manufacturing
Review Questions
Problems
Key words
CASE STUDY Bevel Gear for a Riding Lawn Mower
Readings
31.1 Introduction
31.2 Thread Making
31.3 Internal Thread Cutting–Tapping
31.4 Thread Milling
31.5 Thread Grinding
31.6 Thread Rolling
31.7 Gear Theory and Terminology
31.8 Gear Types
31.9 Gear Manufacturing
31.10 Machining of Gears
31.12 Gear Finishing
31.13 Gear Inspection
Chapter 32: Surface Integrity and Finishing Processes
Review Questions
Problems
Key words
CASE STUDY Dana Lynn’s Fatigue Lesson
Readings
32.1 Introduction
32.2 Surface Integrity
32.3 Abrasive Cleaning and Finishing
32.4 Chemical Cleaning
32.5 Coatings
32.6 Vaporized Metal Coatings
32.7 Clad Materials
32.8 Textured Surfaces
32.9 Coil‐Coated Sheets
32.10 Edge Finishing and Burr Removal
Chapter 33: Additive Processes—Including 3‐D Printing
Review Questions
Problems
Key words
CASE STUDY Golf Club—Irons and Metal “Woods” via Additive Manufacturing
Readings
33.1 Introduction
33.2 Layerwise Manufacturing
33.3 Liquid‐Based Processes
33.4 Powder‐Based Processes
33.5 Deposition‐Based Processes
33.6 Uses and Applications
33.7 Pros, Cons, and Current and Future Trends
33.8 Economic Considerations
Chapter 34: Manufacturing Automation and Industrial Robots
Review Questions
Problems
Key words
Readings
34.1 Introduction
34.2 The A(4) Level of Automation
34.3 A(5) Level of Automation Requires Evaluation
34.4 Industrial Robotics
34.5 Computer‐Integrated Manufacturing (CIM)
34.6 Computer‐Aided Design
34.7 Computer‐Aided Manufacturing
34.8 Summary
Chapter 35: Fundamentals of Joining
Review Questions
Problems
Key words
Readings
35.1 Introduction to Consolidation Processes
35.2 Classification of Welding and Thermal Cutting Processes
35.3 Some Common Concerns
35.4 Types of Fusion Welds and Types of Joints
35.5 Design Considerations
35.6 Heat Effects
35.7 Weldability or Joinability
35.8 Summary
Chapter 36: Gas Flame and Arc Processes
Review Questions
Problems
Key words
CASE STUDY Bicycle Frame Construction and Repair
Readings
36.1 Oxyfuel‐Gas Welding
36.2 Oxygen Torch Cutting
36.3 Flame Straightening
36.4 Arc Welding
36.5 Consumable‐Electrode Arc Welding
36.6 Nonconsumable Electrode Arc Welding
36.7 Other Processes Involving Arcs
36.8 Arc Cutting
36.9 Metallurgical and Heat Effects in Thermal Cutting
36.10 Welding Equipment
36.11 Thermal Deburring
Chapter 37: Resistance and Solid‐State Welding Processes
Review Questions
Problems
Key words
CASE STUDY Manufacture of an Automobile Muffler
Readings
37.1 Introduction
37.2 Theory of Resistance Welding
37.3 Resistance Welding Processes
37.4 Advantages and Limitations of Resistance Welding
37.5 Solid‐State Welding Processes
Chapter 38: Other Welding Processes, Brazing, and Soldering
Review Questions
Problems
Key words
CASE STUDY Impeller of a Pharmaceutical Company Industrial Shredder/Disposal
Readings
38.1 Introduction
38.2 Other Welding and Cutting Processes
38.3 Surface Modification by Welding‐Related Processes
38.4 Brazing
38.5 Soldering
Chapter 39: Adhesive Bonding, Mechanical Fastening, and Joining of Nonmetals
Review Questions
Problems
Key words
CASE STUDY Golf Club Heads with Insert
Readings
39.1 Adhesive Bonding
39.2 Mechanical Fastening
39.3 Joining of Plastics
39.4 Joining of Ceramics and Glass
39.5 Joining of Composites
Chapter 40: JIG and Fixture Design
Review Questions
Problems
Key words
Readings
40.1 Introduction
40.2 Conventional Fixture Design
40.3 Tool Design Steps
40.4 Clamping Considerations
40.5 Chip Disposal
40.6 Example of Jig Design
40.7 Types of Jigs
40.8 Conventional Fixtures
40.9 Modular Fixturing
40.10 Setup and Changeover
40.11 Clamps
40.12 Other Workholding Devices
40.13 Economic Justification of Jigs and Fixtures
Chapter 41: The Enterprise (Production System)
Review Questions
Problems
Key words
Readings
41.1 Introduction
41.2 Typical Functional Areas in the Production System (PS)
Chapter 42: Lean Engineering
Review Questions
Problems
Key words
CASE STUDY Cycle Time for a Manufacturing Cell
Readings
42.1 Introduction
42.2 The Lean Engineer
42.3 The Lean Production System
42.4 Linked‐Cell Manufacturing System Design Rules
42.5 Manufacturing System Designs
42.6 Preliminary Steps to Lean Production
42.7 Methodology for Implementation of Lean Production
42.8 Design Rule MT < CT
42.9 Decouplers
42.10 Integrating Production Control
42.11 Integrating Inventory Control
42.12 Lean Manufacturing Cell Design
42.13 Machine Tool Design for Lean Manufacturing Cells
42.14 L‐CMS Strategy
Chapter 43: Mixed‐Model Final Assembly
Review Questions
Problems
Key words
Readings
43.1 Introduction
43.2 History
43.3 Mixed‐Model Final Assembly
43.4 An Example of MMFA
43.5 Key Enabling Systems
43.6 Manual Assembly Line Balancing
43.7 Sequencing
43.8 Quality in Mixed‐Model Final Assembly
43.9 Examples of Assembly Aids/Poka‐Yoke (Error‐Proofing) Applications
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