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Contents

Preface iii Acronyms xiii 1 Introduction to DeGarmo's Materials and Processes in Manufacturing 1 1.1 Materials, Manufacturing, and the Standard of Living 1 1.2 Manufacturing and Production Systems 2 2 Properties of Materials 23 2.1 Introduction 23 2.2 Static Properties 24 2.3 Dynamic Properties 34 2.4 Temperature Effects (Both High and Low) 39 2.5 Machinability, Formability, and Weldability 42 2.6 Fracture Toughness and the Fracture Mechanics Approach 42 2.7 Physical Properties 43 2.8 Testing Standards and Testing Concerns 43 3 Nature of Materials 45 3.1 Structure-Property-Processing-Performance Relationships 45 3.2 The Structure of Atoms 45 3.3 Atomic Bonding 46 3.4 Secondary Bonds 47 3.5 Atom Arrangements in Materials 48 3.6 Crystal Structures 48 3.7 Development of a Grain Structure 49 3.8 Elastic Deformation 50 3.9 Plastic Deformation 50 3.10 Dislocation Theory of Slippage 52 3.11 Strain Hardening or Work Hardening 53 3.12 Plastic Deformation in Polycrystalline Material 53 3.13 Grain Shape and Anisotropic Properties 54 3.14 Fracture 54 3.15 Cold Working, Recrystallization, and Hot Working 54 3.16 Grain Growth 55 3.17 Alloys and Alloy Types 55 3.18 Atomic Structure and Electrical Properties 56 4 Equilibrium Phase Diagrams and the Iron-Carbon System 57 4.1 Introduction 57 4.2 Phases 57 4.3 Equilibrium Phase Diagrams 57 4.4 Iron-Carbon Equilibrium Diagram 63 4.5 Steels and the Simplified Iron-Carbon Diagram 64 4.6 Cast Irons 65 5 Heat Treatment 67 5.1 Introduction 67 5.2 Processing Heat Treatments 67 5.3 Heat Treatments Used to Increase Strength 69 5.4 Strengthening Heat Treatments for Nonferrous Metals 70 5.5 Strengthening Heat Treatments for Steel 72 5.6 Surface Hardening of Steel 83 5.7 Furnaces 84 5.8 Heat Treatment and Energy 86 6 Ferrous Metals and Alloys 87 6.1 Introduction to History-Dependent Materials 87 6.2 Ferrous Metals 87 6.3 Iron 88 6.4 Steel 88 6.5 Stainless Steels 98 6.6 Tool Steels 100 6.7 Cast Irons 102 6.8 Cast Steels 105 6.9 The Role of Processing on Cast Properties 105 7 Nonferrous Metals and Alloys 106 7.1 Introduction 106 7.2 Copper and Copper Alloys 106 7.3 Aluminum and Aluminum Alloys 111 7.4 Magnesium and Magnesium Alloys 115 7.5 Zinc and Zinc Alloys 118 7.6 Titanium and Titanium Alloys 119 7.7 Nickel-Based Alloys 120 7.8 Superalloys, Refractory Metals, and Other Materials Designed for High-Temperature Service 120 7.9 Lead and Tin and Their Alloys 123 7.10 Some Lesser-Known Metals and Alloys 123 7.11 Metallic Glasses 123 7.12 Graphite 123 7.13 Materials for Specific Applications 124 7.14 High Entropy Alloys 124 8 Nonmetallic Materials: Plastics, Elastomers, Ceramics, and Composites 125 8.1 Introduction 125 8.2 Plastics 125 8.3 Elastomers 135 8.4 Ceramics 137 8.5 Composite Materials 145 9 Material Selection 153 9.1 Introduction 153 9.2 Material Selection and Manufacturing Processes 155 9.3 The Design Process 155 9.4 Approaches to Material Selection 156 9.5 Additional Factors to Consider 158 9.6 Consideration of the Manufacturing Process 159 9.7 Ultimate Objective 159 9.8 Materials Substitution 161 9.9 Effect of Product Liability on Materials Selection 161 9.10 Aids to Material Selection 162 10 Measurement and Inspection 163 10.1 Introduction 163 10.2 Standards of Measurement 163 10.3 Allowance and Tolerance 166 10.4 Inspection Methods for Measurement 171 10.5 Measuring Instruments 172 10.6 Vision Systems 180 10.7 Coordinate Measuring Machines 180 10.8 Angle-Measuring Instruments 181 10.9 Gages for Attributes Measuring 182 11 Nondestructive Examination (NDE) / Nondestructive Testing (NDT) 186 11.1 Destructive vs. Nondestructive Testing 186 11.2 Visual Inspection 187 11.3 Liquid Penetrant Inspection 188 11.4 Magnetic Particle Inspection 189 11.5 Ultrasonic Inspection 190 11.6 Radiography 191 11.7 Eddy-Current Testing 192 11.8 Acoustic Emission Monitoring 194 11.9 Other Methods of Nondestructive Testing and Inspection 195 11.10 Dormant vs. Critical Flaws 196 11.11 Current and Future Trends 196 12 Process Capability and Quality Control 197 12.1 Introduction 197 12.2 Determining Process Capability 198 12.3 Introduction to Statistical Quality Control 204 12.4 Sampling Errors 207 12.5 Gage Capability 208 12.6 Just in Time/Total Quality Control 209 12.7 Six Sigma 217 12.8 Summary 220 13 Fundamentals of Casting 221 13.1 Introduction to Materials Processing 221 13.2 Introduction to Casting 222 13.3 Casting Terminology 223 13.4 The Solidification Process 223 13.5 Patterns 231 13.6 Design Considerations in Castings 232 13.7 The Casting Industry 234 14 Expendable-Mold Casting Processes 236 14.1 Introduction 236 14.2 Sand Casting 236 14.3 Cores and Core Making 249 14.4 Other Expendable-Mold Processes with Multiple- Use Patterns 252 14.5 Expendable-Mold Processes Using Single-Use Patterns 253 14.6 Shakeout, Cleaning, and Finishing 259 14.7 Summary 259 15 Multiple-Use-Mold Casting Processes 260 15.1 Introduction 260 15.2 Permanent-Mold Casting 260 15.3 Die Casting 263 15.4 Squeeze Casting and Semisolid Casting 266 15.5 Centrifugal Casting 267 15.6 Continuous Casting 269 15.7 Melting 269 15.8 Pouring Practice 271 15.9 Cleaning, Finishing, Heat Treating, and Inspection 272 15.10 Automation in Foundry Operations 273 15.11 Process Selection 273 16 Powder Metallurgy (Particulate Processing) 275 16.1 Introduction 275 16.2 The Basic Process 275 16.3 Powder Manufacture 276 16.4 Powder Testing and Evaluation 277 16.5 Powder Mixing and Blending 277 16.6 Compacting 278 16.7 Sintering 281 16.8 Advances in Sintering (Shorter Time, Higher Density, Stronger Products) 282 16.9 Hot-Isostatic Pressing 282 16.10 Other Techniques to Produce High-Density P/M Products 283 16.11 Metal Injection Molding (MIM) 284 16.12 Secondary Operations 285 16.13 Properties of P/M Products 287 16.14 Design of Powder Metallurgy Parts 288 16.15 Powder Metallurgy Products 289 16.16 Advantages and Disadvantages of Powder Metallurgy 290 16.17 Process Summary 291 17 Fundamentals of Metal Forming 292 17.1 Introduction 292 17.2 Forming Processes: Independent Variables 292 17.3 Dependent Variables 293 17.4 Independent-Dependent Relationships 294 17.5 Process Modeling 295 17.6 General Parameters 295 17.7 Friction, Lubrication, and Wear under Metalworking Conditions 296 17.8 Temperature Concerns 297 17.9 Formability 303 18 Bulk-Forming Processes 304 18.1 Introduction 304 18.2 Classification of Deformation Processes 304 18.3 Bulk Deformation Processes 304 18.4 Rolling 305 18.5 Forging 309 18.6 Extrusion 318 18.7 Wire, Rod, and Tube Drawing 322 18.8 Cold Forming, Cold Forging, and Impact Extrusion 324 18.9 Piercing 327 18.10 Other Squeezing Processes 328 18.11 Surface Improvement by Deformation Processing 330 19 Sheet-Forming Processes 331 19.1 Introduction 331 19.2 Shearing Operations 331 19.3 Bending 337 19.4 Drawing and Stretching Processes 343 19.5 Alternative Methods of Producing Sheet-Type Products 353 19.6 Seamed Pipe Manufacture 354 19.7 Presses 354 20 Fabrication of Plastics, Ceramics, and Composites 359 20.1 Introduction 359 20.2 Fabrication of Plastics 359 20.3 Processing of Rubber and Elastomers 369 20.4 Processing of Ceramics 369 20.5 Fabrication of Composite Materials 372 21 Fundamentals of Machining/ Orthogonal Machining 381 21.1 Introduction 381 21.2 Fundamentals 381 21.3 Forces and Power in Machining 386 21.4 Orthogonal Machining (Two Forces) 390 21.5 Chip Thickness Ratio, rc 394 21.6 Mechanics of Machining (Statics) 395 21.7 Shear Strain, ?, and Shear Front Angle, ? 397 21.8 Mechanics of Machining (Dynamics) (Section courtsey of Dr. Elliot Stern) 399 22 Cutting Tool Materials 405 22.1 Cutting Tool Materials 408 22.2 Tool Geometry 417 22.3 Tool-Coating Processes 419 22.4 Tool Failure and Tool Life 420 22.5 Taylor Tool Life 421 22.6 Cutting Fluids 425 22.7 Economics of Machining 426 23 Turning and Boring Processes 428 23.1 Introduction 428 23.2 Fundamentals of Turning, Boring, and Facing Turning 430 23.3 Lathe Design and Terminology 434 23.4 Cutting Tools for Lathes 438 23.5 Workholding in Lathes 442 24 Milling 447 24.1 Introduction 447 24.2 Fundamentals of Milling Processes 447 24.3 Milling Tools and Cutters 453 24.4 Machines for Milling 457 25 Drilling and Related Hole-Making Processes 462 25.1 Introduction 462 25.2 Fundamentals of the Drilling Process 463 25.3 Types of Drills 464 25.4 Tool Holders for Drills 472 25.5 Workholding for Drilling 474 25.6 Machine Tools for Drilling 475 25.7 Cutting Fluids for Drilling 478 25.8 Counterboring, Countersinking, and Spot Facing 479 25.9 Reaming 480 26 CNC Processes and Adaptive Control: A(4) and A(5) Levels of Automation 482 26.1 Introduction 482 26.2 Basic Principles of Numerical Control 482 26.3 CNC Part Programming 488 26.4 Interpolation and Adaptive Control 494 26.5 Machining Center Features and Trends 497 26.6 Summary 501 27 Sawing, Broaching, Shaping, and Filing Machining Processes 502 27.1 Introduction 502 27.2 Introduction to Sawing 502 27.3 Introduction to Broaching 510 27.4 Fundamentals of Broaching 512 27.5 Broaching Machines 516 27.6 Introduction to Shaping and Planing 516 27.7 Introduction to Filing 520 28 Abrasive Machining Processes 523 28.1 Introduction 523 28.2 Abrasives 524 28.3 Grinding Wheel Structure and Grade 528 28.4 Grinding Wheel Identification 531 28.5 Grinding Machines 534 28.6 Honing 540 28.7 Superfinishing 542 28.8 Free Abrasives 543 28.9 Design Considerations in Grinding 547 29 Nano and Micro-Manufacturing Processes 548 29.1 Introduction 548 29.2 Lithography 551 29.3 Micromachining Processes 554 29.4 Deposition Processes 556 29.5 How ICs Are Made 562 29.6 Nano- and Micro-Scale Metrology 568 30 Nontraditional Manufacturing Processes 570 30.1 Introduction 570 30.2 Chemical Machining Processes 572 30.3 Electrochemical Machining Processes 576 30.4 Electrical Discharge Machining 581 31 Thread and Gear Manufacturing 589 31.1 Introduction 589 31.2 Thread Making 592 31.3 Internal Thread Cutting-Tapping 595 31.4 Thread Milling 597 31.5 Thread Grinding 599 31.6 Thread Rolling 599 31.7 Gear Theory and Terminology 601 31.8 Gear Types 603 31.9 Gear Manufacturing 604 31.10 Machining of Gears 605 31.12 Gear Finishing 610 31.13 Gear Inspection 611 32 Surface Integrity and Finishing Processes 613 32.1 Introduction 613 32.2 Surface Integrity 613 32.3 Abrasive Cleaning and Finishing 620 32.4 Chemical Cleaning 624 32.5 Coatings 626 32.6 Vaporized Metal Coatings 633 32.7 Clad Materials 633 32.8 Textured Surfaces 633 32.9 Coil-Coated Sheets 633 32.10 Edge Finishing and Burr Removal 634 33 Additive Processes-Including 3-D Printing 637 33.1 Introduction 637 33.2 Layerwise Manufacturing 638 33.3 Liquid-Based Processes 641 33.4 Powder-Based Processes 643 33.5 Deposition-Based Processes 647 33.6 Uses and Applications 649 33.7 Pros, Cons, and Current and Future Trends 652 33.8 Economic Considerations 655 34 Manufacturing Automation and Industrial Robots 656 34.1 Introduction 656 34.2 The A(4) Level of Automation 660 34.3 A(5) Level of Automation Requires Evaluation 666 34.4 Industrial Robotics 669 34.5 Computer-Integrated Manufacturing (CIM) 675 34.6 Computer-Aided Design 677 34.7 Computer-Aided Manufacturing 678 34.8 Summary 679 35 Fundamentals of Joining 680 35.1 Introduction to Consolidation Processes 680 35.2 Classification of Welding and Thermal Cutting Processes 681 35.3 Some Common Concerns 681 35.4 Types of Fusion Welds and Types of Joints 681 35.5 Design Considerations 682 35.6 Heat Effects 684 35.7 Weldability or Joinability 688 35.8 Summary 689 36 Gas Flame and Arc Processes 690 36.1 Oxyfuel-Gas Welding 690 36.2 Oxygen Torch Cutting 693 36.3 Flame Straightening 694 36.4 Arc Welding 695 36.5 Consumable-Electrode Arc Welding 696 36.6 Nonconsumable Electrode Arc Welding 702 36.7 Other Processes Involving Arcs 706 36.8 Arc Cutting 707 36.9 Metallurgical and Heat Effects in Thermal Cutting 709 36.10 Welding Equipment 710 36.11 Thermal Deburring 711 37 Resistance and Solid-State Welding Processes 712 37.1 Introduction 712 37.2 Theory of Resistance Welding 712 37.3 Resistance Welding Processes 714 37.4 Advantages and Limitations of Resistance Welding 717 37.5 Solid-State Welding Processes 718 38 Other Welding Processes, Brazing, and Soldering 726 38.1 Introduction 726 38.2 Other Welding and Cutting Processes 726 38.3 Surface Modification by Welding-Related Processes 732 38.4 Brazing 735 38.5 Soldering 742 39 Adhesive Bonding, Mechanical Fastening, and Joining of Nonmetals 746 39.1 Adhesive Bonding 746 39.2 Mechanical Fastening 752 39.3 Joining of Plastics 755 39.4 Joining of Ceramics and Glass 758 39.5 Joining of Composites 758 40 JIG and Fixture Design W 1 41 The Enterprise (Production System) W 20 42 Lean Engineering W 35 43 Mixed-Model Final Assembly W 65 Index I- 1

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