Manufacturing Engineering And Technology - GBV

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ManufacturingEngineeringand TechnologySEVENTHEDITIONIN SI UNITSSerope KalpakjianIllinois Instituteof TechnologySteven R. SchmidTheUniversity of Notre DameSI Edition ContributionsK. S.SSNbyVijay SekarCollege of Engineering, Chennai, IndiaSingaporeMexico CityLondonMunichNew YorkParisTorontoCape TownSydneyTokyoHong KongMadridMontreal

ContentsxxiiiPrefaceAbout the AuthorsxxviiGeneral Introduction11.1What is1.2Product1.3Design for Manufacture, Assembly, Disassembly, andManufacturing?Design1and ConcurrentDesign and Manufacturing1.4Green1.5Selection of Materials1.6Selection of Manufacturing Processes1.7Assurance and TotalQuality1.9Lean Production and1.10Manufacturing1.11Trends inService101113Computer-integrated Manufacturing1.86Engineering1625Quality ManagementAgile ManufacturingCosts and GlobalManufacturing283031Competition32Parti: Fundamentals of Materials: Behaviorand1The Structure of Metals381.1Introduction1.2Types of Atomic Bonds1.3The1.4Deformation and1.5Grains and Grain Boundaries1.6Plastic Deformation of1.7Recovery, Recrystallization, and1.838StrengthWarm, and Hot51Review39Structure of MetalsCrystalCold,Summary35Manufacturing PropertiesKeyTerms52QuestionsQuantitative Problems2.2Tension45Working51Grain thesis, Design, and Projects53Testing,Properties of MaterialsIntroduction42Single CrystalsPolycrystalline MetalsMechanical Behavior,2.1of40and54Manufacturing555556v

2.3Compression2.4Torsion2.5Bending 2.9Impact2.10Failure and Fracture of Materials2.11Residual Stresses2.12Work, Heat, and .2QualitativeSynthesis, Design, and Projectsof ermal3.6Thermal3.7Electrical, Magnetic,3.8Corrosion ResistanceSummary929393Expansion94Optical titative 786883.3Review838485Physical titative Problems3.17599Problems9898Synthesis, Design, and ProjectsTheir Structure and99Strengthening101by Heat Treatment4.1Introduction4.2Structure of4.3Phase4.4The Iron-carbon4.5The Iron-iron-carbide Phase Diagram and the101102AlloysDiagrams104107Systemof Microstructures in Steels4.6Cast Irons4.7Heat Treatment of Ferrous108109of FerrousAlloys4.8Hardenability4.9Heat Treatment of Nonferrousand Stainless 12Heat-treating Furnaces and Equipment4.13Design Considerations forHardening119121HeatTreating123124Development

Summary125Key Terms126Bibliography126Qualitative Problems 127Questions 126Synthesis, Design, and ProjectsQuantitative Problems 127ReviewFerrous Metals andProperties,andAlloys: Production,Introduction5.2Production of Iron and ntinuous5.5Carbon and5.6Stainless Steels5.7Tool and Die 4TermsKeySummaryQuestions 147Quantitative tiveSynthesis, Design, and Projects148Nonferrous Metals and148Alloys: Production,General Properties, and Applications6.1Introduction6.2Aluminum and Aluminum6.3Magnesium and Magnesium Alloys150150Alloys1511556.4Copper and Copper Alloys6.5Nickel and Nickel6.6Superalloys6.7Titanium and Low-melting Alloys6.12Precious Metals6.13Shape-memory Alloys (Smart Materials)6.14Amorphous Alloys (Metallic Glasses)6.15Metal FoamsAlloys156158159Metals andAlloysAlloys160161162162162164164165165Key Terms 166Bibliography 166167Qualitative Problems 167Synthesis, Design, and ProjectsQuantitative Problems 167Summary127166Review QuestionsPolymers: Structure,and169Applications7.1Introduction7.2The Structure of7.3ThermoplasticsGeneral Properties,169Polymers178171168

viiiContents1817.4Thermosetting Plastics7.5Additives in Plastics7.6General Properties and Applicationsof Thermoplastics1837.7Generalof182Properties and ApplicationsThermosetting Plastics 186Plastics7.8Biodegradable7.9Elastomers (Rubbers)187188Key Terms 190Bibliography 190Review Questions191Qualitative Problems 191Synthesis, Design, and Projects,Quantitative Problems 192Summary8189193Ceramics, Glass, Graphite, Diamond, andNanomaterials: Structure, General The Structure of Ceramics8.3GeneralProperties and Applicationsof Ceramics2008.4Glasses8.5Glass ve lems212213Synthesis, Design, and ProjectsCompositeMaterials: Structure, tion9.2The Structure of Reinforced Plastics2159.3Properties of Reinforced Plastics221of Reinforced 16228229Summary 230Key Terms 230Bibliography 230231Review QuestionsQualitative Problems 231Quantitative Problems 232Synthesis, Design, and Projects232

Part II:10Metal-casting Processes235and EquipmentFundamentals of Metal10.1Introduction10.2Solidification of Metals10.3Fluid Flow10.4Fluidity of Molten Metal10.5Heat maryKey Terms 252Bibliography 253Problems253253QualitativeQuestionsQuantitative Problems 254Synthesis, Design, and Projects252ReviewProcesses d, Permanent-pattern ting Processes11.5Casting Techniques11.6Rapid SolidificationofforInspection11.8Melting Practice and11.9Foundries andSummary289ReviewKey284287Furnaces287Foundry AutomationQuestionsQuantitative ems290291Synthesis, Design, and Projects292Casting: Design, Materials,and EconomicsIntroduction294294Considerations in12.2Design12.3Casting Alloys12.4Economics of309SummaryQuestionsReviewSingle-crystal ble-mold, Expendable-pattern CastingProcesses2Equipment255Key TermsQuantitative roblems309310QualitativeSynthesis, Design, and Projects310311

ContentsPart III:and13andFormingProcesses and13.1Introduction13.2The13.3Flat-rolling PracticeEquipmentFlat-rolling SummaryKeyReview Questions334Quantitative ProblemsProcesses and MillsTerms333328Qualitative334Synthesis, Design,335334BibliographyProblemsProcesses on14.2Open-die Forging14.3Impression-die and Closed-die Forging14.4Various14.5Forgeability of Metals; Forging Defects14.6Die336337337339Forging ingProcessesShapingDie342345349Materials, and Lubrication14.7Die-manufacturing14.8Forging Machines14.9Economics ofMethods and Die Failure351354355358ForgingSummary 360Key Terms 361Bibliography 2Synthesis, Design,ProjectsQuantitativeReview15Metal Extrusion andand e Extrusion Process15.3Hot Extrusion15.4Cold Extrusion15.5Extrusion Defects15.6Design Considerations15.7Extrusion36415.8The15.9Drawing Practice366368372374376Equipment376Drawing Process377379Defects and Residual Stresses15.10Drawing15.11Drawing Equipment383Terms382382384Bibliography 384Questions 384Qualitative Problems 384Quantitative Problems 385Synthesis, Design, and ProjectsSummary363KeyReview385

oduction38638716.2Shearing16.3Sheet-metal Characteristics andFormabilityTests for Sheet Metals16.4Formability16.5Bending Sheets, Plates, and Tubes16.6MiscellaneousBending16.7Deep Drawing41116.8Rubber16.9397399402and Related FormingForming and lastic Forming16.11Hot16.12Specialized Forming Processes16.13Manufacturing of Metal Honeycomb Structures16.14Design Considerations in Sheet-metal Forming16.15Equipment16.16Economics ofStamping426427for Sheet-metal428433434437FormingSheet-forming Operations438Bibliography 440Key Terms 440Summary 1Synthesis, Design,QuantitativeProjectsReviewPowder Metal Processes and17.1Introduction17.2Production of Metal Powders17.3Compaction17.4444Equipment444445of Metal PowdersSintering46117.5Secondaryand17.6Design Considerations17.7Economics of Powder471Quantitative Problems450Finishing OperationsKeySummaryReview Questions 471472QualitativeSynthesis, Design, and Projects473Ceramics, Glasses, and Superconductors:Processing and Equipment 3Forming and Shaping of Glass483andAnnealing Glass18.4Techniques for Strengthening18.5Design Considerations for Ceramics and Glasses18.6Processing of Superconductors489486489473

xiiContentsKey Terms 491Bibliography 3Synthesis, cs andandMaterials:CompositeShaping 49419.1Introduction19.2Extrusion19.3Injection Compression 514Molding515Forming and Solid-phase FormingProcessing19.13Processing Polymer-matrix Composites19.14Processing Metal-matrix and Ceramic-matrixComposites 52719.15Design Considerations19.16Economics estionsIntroductionSubtractive Processes20.3Additive turingQuestionsKey561Quantitative atingBibliographyProcesses20.120.5531Qualitative Problems 532533Synthesis, Design, and Review518Processing Plastics and CompositeKey560517530Quantitative Problemsand493Termsand552Rapid Tooling560553Bibliography560Qualitative Problems 561Synthesis, Design, and Projects562562

Part IV:Processes and MachineMachining563ToolsFundamentals ofMachining21.1Introduction21.2Mechanics of Cutting566566567Forces and Power21.3Cutting57721.4Temperatures in Cutting21.5Tool Life: Wear and Failure58221.6Surface Finish ummaryKeyBibliography dQuantitativeSynthesis, Design,ProjectsReview22Cutting-toolMaterials andFluids22.1Introduction22.2High-speed Steels22.3Cast-cobalt22.4Carbides22.5Coated Tools22.6Alumina-based Ceramics22.7Cubic Boron Nitride22.8Silicon-nitride-based Ceramics22.9Diamond22.10Whisker-reinforced Materials and Nanomaterials22.11Tool Costs and22.12Cutting ntitative Problemsof ProblemsSynthesis, Design, and ProjectsMachining Processes: TurningMaking 625and Hole23.1Introduction23.2The23.3Lathes and Lathe23.4Boring and Boring Machines23.5Drilling, Drills, and Drilling Machines625Turning Process622623628Operations636651652624

and Reamers23.6Reaming23.7Tapping and Taps664SummaryReview QuestionsMachiningFiling, ative Problems24661Problems665666Synthesis, Design, and Projects666667Processes:Milling, Broaching, Sawing,Manufacturing 668Gear24.1Introduction24.2Milling24.3Planing and 8692Manufacturing by Machining692Summary 699Key Terms 700Bibliography 700Questions 700Qualitative Problems 700Quantitative Problems 701Synthesis, Design, and ProjectsReview25Machining Centers, Machine-tool Structures,and Machining Economics70325.1Introduction25.2Machining Centers25.3Machine-tool Structures25.4Vibration and Chatter inMachining Operations25.5High-speed Machining71925.6Hard25.7Ultraprecision 721722Terms726Key727QuestionsQuantitative lems727727QualitativeSynthesis, Design, and Projects728AbrasiveMachiningOperations 729andFinishing26.1Introduction72926.2Abrasives and Bonded Abrasives26.3TheGrinding Process73173726.4Grinding Operationsand Machines74626.5Design Considerations for Grinding75526.6Ultrasonic26.7Finishing OperationsMachining755756728

Contents26.8Deburring Operations26.9Economics of Abrasive761Machining and Finishing OperationsBibliographyKeySummaryQualitative Problems 767Questions 766Quantitative Problems 767Synthesis, Design, and Projects765Terms765766ReviewAdvancedMachiningand ding27.5Electrical-discharge jet Machining27.9Abrasive-jet Machining27.10Hybrid Machining Systems27.11Economics of hining788790790Machining Processes791Bibliography 795Summary 794Key Terms 794Review Questions795Qualitative Problems 795Problems796QuantitativeSynthesis, Design, and ProjectsPartV:797Fabrication of Microelectronic Devices28.1Introduction28.2Clean Rooms28.3Semiconductors and Silicon28.4Crystal Growing and Wafer 8Etching28.9Diffusion and IonImplantation28.10Metallization andTesting28.11Wire28.12Yield and28.13Printed Circuit ckagingReliabilityKeySummaryQuestions 838Quantitative ProblemsReview800800Deposition837796and FabricationMicromanufacturingof Microelectronic ativeSynthesis, Design,839838839andProjects840764xv

Fabrication of Microelectromechanical Devices841and Systems; Nanoscale Man

Manufacturing Engineering andTechnology SEVENTH EDITION IN SI UNITS SeropeKalpakjian Illinois Institute ofTechnology StevenR. Schmid The University ofNotreDame SI Edition Contributions by K. S. Vijay Sekar SSN College ofEngineering, Chennai, India Singapore London NewYork Toronto Sydney Tokyo Madrid Mexico City Munich Paris Cape Town Hong Kong Montreal