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A01 KALP8609 08 SE FMpage iManufacturingEngineeringand Technology EIGHTHEDITIONSerope KalpakjianIllinois Institute of TechnologySteven R. SchmidThe University of Notre Dame

A01 KALP8609 08 SE FMpage iiSenior Vice President Courseware Portfolio Management: Marcia J. HortonVice President Portfolio Management Engineering & Computer Science, Global Editions: Julian PartridgeExecutive Portfolio Manager: Holly StarkPortfolio Management Assistant: Amanda PerfitField Marketing Manager: Demetrius HallProduct Marketing Manager: Yvonne VannattaMarketing Assistant: Jon BryantManager, Rights and Permissions: Ben FerriniManaging Producer: Scott DisannoContent Producer: Amanda BrandsSenior Digital Content Producer: Sandra RodriguezInventory Manager: Bruce BoundyCover Designer: Black Horse DesignsCover Photo: Getty Images/Olaf Pappers/EyeEmComposition: Integra Software Services Pvt. Ltd.Project Manager: Yohalakshmi Segar, Integrac 2020, 2014, 2010, 2006 by Pearson, Hoboken, NJ 07030Copyright All rights reserved. Printed in the United States of America. This publication is protected by copyright, and permission should be obtained from thepublisher prior to any prohibited reproduction, storage in a retrieval system, or transmission in any form or by any means, electronic, mechanical,photocopying, recording, or otherwise. For information regarding permissions, request forms and the appropriate contacts within the PearsonEducation Global Rights & Permissions department, please visit www.pearsonhighed.com/permissions/.Many of the designations by manufacturers and seller to distinguish their products are claimed as trademarks. Where those designations appear in thisbook, and the publisher was aware of a trademark claim, the designations have been printed in initial caps or all caps.The author and publisher of this book have used their best efforts in preparing this book. These efforts include the development, research, and testing oftheories and programs to determine their effectiveness. The author and publisher make no warranty of any kind, expressed or implied, with regard tothese programs or the documentation contained in this book. The author and publisher shall not be liable in any event for incidental or consequentialdamages with, or arising out of, the furnishing, performance, or use of these programs.Library of Congress Cataloging-in-Publication DataKalpakjian, Serope, 1928Manufacturing engineering and technology / Serope Kalpakjian, Illinois Institute of Technology, Steven R. Schmid,The University of Notre Dame.—Eighth edition.pages cmISBN-13: 978-0-13-522860-9ISBN-10: 0-13-522860-31. Production engineering. 2. Manufacturing processes. I. Schmid, Steven R. II. Title.TS176.K34 2012670.42—dc23ISBN-13: 978-0-13-522860-9ISBN-10:0-13-522860-3

A01 KALP8609 08 SE FMpage iiiDedicated to our families, whose patience andsupport made this book possible.

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A01 KALP8609 08 SE FMpage vContents PrefacexxiiiAbout the AuthorsxxviGeneral at is Manufacturing? 1Product Design and Concurrent Engineering 8Design for Manufacture, Assembly, Disassembly, and Service 13Environmentally Conscious Design, Sustainable Manufacturing,and Product Life Cycle 14Selection of Materials 16Selection of Manufacturing Processes 18Computer-integrated Manufacturing 26Quality Assurance and Total Quality Management 29Lean Production and Agile Manufacturing 31Manufacturing Costs and Global Competition 31Trends in Manufacturing 33Part I: Fundamentals of Materials: Behaviorand Manufacturing Properties 351The Structure of Metals371.1Introduction 371.2Types of Atomic Bonds 391.3The Crystal Structure of Metals 391.4Deformation and Strength of Single Crystals 411.5Grains and Grain Boundaries 451.6Plastic Deformation of Polycrystalline Metals 471.7Recovery, Recrystallization, and Grain Growth 491.8Cold, Warm, and Hot Working 50Summary 51Key Terms 51Bibliography 52Review Questions 52Qualitative Problems 53Quantitative Problems 54Synthesis, Design, and Projects 552Mechanical Behavior, Testing, and ManufacturingProperties of Materials 562.12.2IntroductionTension 5757v

A01 KALP8609 08 SE FMpage viviContents2.3Compression 682.4Torsion 702.5Bending (Flexure) 702.6Hardness 712.7Fatigue 762.8Creep 792.9Impact 792.10Failure and Fracture of Materials 802.11Residual Stresses 862.12Work, Heat, and Temperature 88Summary 88Key Terms 89Bibliography 90Review Questions 90Qualitative Problems 91Quantitative Problems 93Synthesis, Design, and Projects 953Physical Properties of Materials973.1Introduction 973.2Density 983.3Melting Point 983.4Specific Heat 993.5Thermal Conductivity 1013.6Thermal Expansion 1013.7Electrical, Magnetic, and Optical Properties 1033.8Corrosion Resistance 104Summary 106Key Terms 106Bibliography 107Review Questions 107Qualitative Problems 107Quantitative Problems 108Synthesis, Design, and Projects 1094Metal Alloys: Their Structure and Strengtheningby Heat Treatment oduction 111Structure of Alloys 112Phase Diagrams 113The Iron-Carbon System 116The Iron–Iron-carbide Phase Diagram and the Development of Microstructuresin Steels 117Cast Irons 119Heat Treatment of Ferrous Alloys 121Hardenability of Ferrous Alloys 123Heat Treatment of Nonferrous Alloys and Stainless Steels 127Case Hardening 129Annealing 129Heat-treating Furnaces and Equipment 133Design Considerations for Heat Treating 134

A01 KALP8609 08 SE FMpage viiContentsSummary 134Key Terms 135Bibliography 136Review Questions 136Qualitative Problems 137Quantitative Problems 137Synthesis, Design, and Projects 1385Ferrous Metals and Alloys: Production, GeneralProperties, and Applications 1395.1Introduction 1395.2Production of Iron and Steel 1405.3Casting of Ingots 1435.4Continuous Casting 1445.5Carbon and Alloy Steels 1465.6Stainless Steels 1535.7Tool and Die Steels 155Summary 157Key Terms 158Bibliography 158Review Questions 159Qualitative Problems 159Quantitative Problems 160Synthesis, Design, and Projects 1606Nonferrous Metals and Alloys:Production, General Properties,and Applications 1626.1Introduction 1636.2Aluminum and Aluminum Alloys 1656.3Magnesium and Magnesium Alloys 1686.4Copper and Copper Alloys 1696.5Nickel and Nickel Alloys 1706.6Superalloys 1716.7Titanium and Titanium Alloys 1726.8Refractory Metals and Alloys 1736.9Beryllium 1746.10Zirconium 1756.11Lithium 1756.12Low-melting Alloys 1756.13Precious Metals 1766.14Shape-memory Alloys (Smart Materials) 1776.15Amorphous Alloys (Metallic Glasses) 1776.16Metal Foams and Metamaterials 1776.17Rare Earth Metals 179Summary 179Key Terms 180Bibliography 180Review Questions 181Qualitative Problems 181Quantitative Problems 182Synthesis, Design, and Projects 182vii

A01 KALP8609 08 SE FMpage viiiviii7ContentsPolymers: Structure, General Properties,and Applications 1847.1Introduction 1857.2The Structure of Polymers 1857.3Thermoplastics 1947.4Thermosetting Plastics 1987.5Additives in Plastics 1987.6General Properties and Applications of Thermoplastics 1997.7General Properties and Applications of Thermosetting Plastics7.8Biodegradable Plastics 2037.9Elastomers (Rubbers) 2047.10Gels 205Summary 205Key Terms 206Bibliography 207Review Questions 207Qualitative Problems 208Quantitative Problems 209Synthesis, Design, and Projects 2098Ceramics, Glass, Graphite, Diamond, andNanomaterials: Structure, General Properties,and Applications 2118.1Introduction 2128.2The Structure of Ceramics 2128.3General Properties and Applications of Ceramics 2178.4Glasses 2218.5Glass Ceramics 2238.6Graphite 2238.7Diamond 2258.8Nanomaterials 226Summary 227Key Terms 228Bibliography 228Review Questions 229Qualitative Problems 230Quantitative Problems 230Synthesis, Design, and Projects 2319Composite Materials: Structure, GeneralProperties, and Applications 2329.1Introduction 2339.2The Structure of Reinforced Plastics 2339.3Properties of Reinforced Plastics 2389.4Applications of Reinforced Plastics 2419.5Metal-matrix Composites 2439.6Ceramic-matrix Composites 2459.7Other Composites 245Summary 246Key Terms 247Bibliography 247Review Questions 248Qualitative Problems 248Quantitative Problems 249Synthesis, Design, and Projects 250201

A01 KALP8609 08 SE FMpage ixixContentsPart II: Metal-casting Processesand Equipment 25310Fundamentals of Metal Casting25510.1Introduction 25610.2Solidification of Metals 25610.3Fluid Flow 26110.4Fluidity of Molten Metal 26510.5Heat Transfer 26610.6Defects 269Summary 272Key Terms 273Bibliography 273Review Questions 274Qualitative Problems 274Quantitative Problems 276Synthesis, Design, and Projects 27711Metal-casting Processes and Equipment27811.1Introduction 27911.2Expendable-mold, Permanent-pattern Casting Processes 28011.3Expendable-mold, Expendable-pattern Casting Processes 29011.4Permanent-mold Casting Processes 29511.5Casting Techniques for Single-crystal Components 30511.6Rapid Solidification 30711.7Inspection of Castings 30711.8Melting Practice and Furnaces 30811.9Foundries and Foundry Automation 309Summary 309Key Terms 310Bibliography 310Review Questions 311Qualitative Problems 311Quantitative Problems 312Synthesis, Design, and Projects 31412Metal Casting: Design, Materials,and Economics 31612.1Introduction 31612.2Design Considerations in Casting 31712.3Casting Alloys 32512.4Economics of Casting 330Summary 330Key Terms 331Bibliography 331Review Questions 331Qualitative Problems 332Quantitative Problems 332Synthesis, Design, and Projects 333

A01 KALP8609 08 SE FMpage xxContentsPart III: Forming and Shaping Processesand Equipment 33713Metal-rolling Processes and Equipment33913.1Introduction 33913.2The Flat-rolling Process 34113.3Flat-rolling Practice 34713.4Rolling Mills 35013.5Various Rolling Processes and Mills 352Summary 357Key Terms 358Bibliography 358Review Questions 359Qualitative Problems 359Quantitative Problems 360Synthesis, Design, and Projects 36114Metal-forging Processes and Equipment36214.1Introduction 36314.2Open-die Forging 36414.3Impression-die and Closed-die Forging 36714.4Various Forging Operations 37114.5Forgeability of Metals; Forging Defects 37514.6Die Design, Die Materials, and Lubrication 37714.7Die-manufacturing Methods and Die Failures 37914.8Forging Machines 38114.9Economics of Forging 382Summary 386Key Terms 386Bibliography 387Review Questions 387Qualitative Problems 387Quantitative Problems 388Synthesis, Design, and Projects 38915Metal Extrusion and Drawing Processesand Equipment 39115.1Introduction 39215.2The Extrusion Process 39315.3Hot Extrusion 39615.4Cold Extrusion 39915.5Extrusion Defects 40215.6Design Considerations 40415.7Extrusion Equipment 40515.8The Drawing Process 40715.9Drawing Practice 40815.10 Drawing Defects and Residual Stresses 41015.11 Drawing Equipment 410Summary 412Key Terms 412Bibliography 412Review Questions 413Qualitative Problems 413Quantitative Problems 414Synthesis, Design, and Projects 415