DeGarmo's Materials and Processes in Manufacturing

Häftad, Engelska, 2021

Av J. T. Black, Ronald A. Kohser, J. T. (Auburn University) Black, Rolla) Kohser, Ronald A. (University of Missouri, J T Black

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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.

Produktinformation

Utgivningsdatum2021-03-02
Mått203 x 252 x 36 mm
Vikt1 520 g
FormatHäftad
SpråkEngelska
Antal sidor896
Upplaga13
FörlagJohn Wiley & Sons Inc
ISBN9781119723295

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Maskinteknik och material inom Naturvetenskap och teknik

Preface iiiAcronyms xiii1 Introduction to DeGarmo’s Materials and Processes in Manufacturing 11.1 Materials, Manufacturing, and the Standard of Living 11.2 Manufacturing and Production Systems 22 Properties of Materials 232.1 Introduction 232.2 Static Properties 242.3 Dynamic Properties 342.4 Temperature Effects (Both High and Low) 392.5 Machinability, Formability, and Weldability 422.6 Fracture Toughness and the Fracture Mechanics Approach 422.7 Physical Properties 432.8 Testing Standards and Testing Concerns 433 Nature of Materials 453.1 Structure—Property—Processing—Performance Relationships 453.2 The Structure of Atoms 453.3 Atomic Bonding 463.4 Secondary Bonds 473.5 Atom Arrangements in Materials 483.6 Crystal Structures 483.7 Development of a Grain Structure 493.8 Elastic Deformation 503.9 Plastic Deformation 503.10 Dislocation Theory of Slippage 523.11 Strain Hardening or Work Hardening 533.12 Plastic Deformation in Polycrystalline Material 533.13 Grain Shape and Anisotropic Properties 543.14 Fracture 543.15 Cold Working, Recrystallization, and Hot Working 543.16 Grain Growth 553.17 Alloys and Alloy Types 553.18 Atomic Structure and Electrical Properties 564 Equilibrium Phase Diagrams and the Iron–Carbon System 574.1 Introduction 574.2 Phases 574.3 Equilibrium Phase Diagrams 574.4 Iron–Carbon Equilibrium Diagram 634.5 Steels and the Simplified Iron–Carbon Diagram 644.6 Cast Irons 655 Heat Treatment 675.1 Introduction 675.2 Processing Heat Treatments 675.3 Heat Treatments Used to Increase Strength 695.4 Strengthening Heat Treatments for Nonferrous Metals 705.5 Strengthening Heat Treatments for Steel 725.6 Surface Hardening of Steel 835.7 Furnaces 845.8 Heat Treatment and Energy 866 Ferrous Metals and Alloys 876.1 Introduction to History-Dependent Materials 876.2 Ferrous Metals 876.3 Iron 886.4 Steel 886.5 Stainless Steels 986.6 Tool Steels 1006.7 Cast Irons 1026.8 Cast Steels 1056.9 The Role of Processing on Cast Properties 1057 Nonferrous Metals and Alloys 1067.1 Introduction 1067.2 Copper and Copper Alloys 1067.3 Aluminum and Aluminum Alloys 1117.4 Magnesium and Magnesium Alloys 1157.5 Zinc and Zinc Alloys 1187.6 Titanium and Titanium Alloys 1197.7 Nickel-Based Alloys 1207.8 Superalloys, Refractory Metals, and Other Materials Designed for High-Temperature Service 1207.9 Lead and Tin and Their Alloys 1237.10 Some Lesser-Known Metals and Alloys 1237.11 Metallic Glasses 1237.12 Graphite 1237.13 Materials for Specific Applications 1247.14 High Entropy Alloys 1248 Nonmetallic Materials: Plastics, Elastomers, Ceramics, and Composites 1258.1 Introduction 1258.2 Plastics 1258.3 Elastomers 1358.4 Ceramics 1378.5 Composite Materials 1459 Material Selection 1539.1 Introduction 1539.2 Material Selection and Manufacturing Processes 1559.3 The Design Process 1559.4 Approaches to Material Selection 1569.5 Additional Factors to Consider 1589.6 Consideration of the Manufacturing Process 1599.7 Ultimate Objective 1599.8 Materials Substitution 1619.9 Effect of Product Liability on Materials Selection 1619.10 Aids to Material Selection 16210 Measurement and Inspection 16310.1 Introduction 16310.2 Standards of Measurement 16310.3 Allowance and Tolerance 16610.4 Inspection Methods for Measurement 17110.5 Measuring Instruments 17210.6 Vision Systems 18010.7 Coordinate Measuring Machines 18010.8 Angle-Measuring Instruments 18110.9 Gages for Attributes Measuring 18211 Nondestructive Examination (NDE) / Nondestructive Testing (NDT) 18611.1 Destructive vs. Nondestructive Testing 18611.2 Visual Inspection 18711.3 Liquid Penetrant Inspection 18811.4 Magnetic Particle Inspection 18911.5 Ultrasonic Inspection 19011.6 Radiography 19111.7 Eddy-Current Testing 19211.8 Acoustic Emission Monitoring 19411.9 Other Methods of Nondestructive Testing and Inspection 19511.10 Dormant vs. Critical Flaws 19611.11 Current and Future Trends 19612 Process Capability and Quality Control 19712.1 Introduction 19712.2 Determining Process Capability 19812.3 Introduction to Statistical Quality Control 20412.4 Sampling Errors 20712.5 Gage Capability 20812.6 Just in Time/Total Quality Control 20912.7 Six Sigma 21712.8 Summary 22013 Fundamentals of Casting 22113.1 Introduction to Materials Processing 22113.2 Introduction to Casting 22213.3 Casting Terminology 22313.4 The Solidification Process 22313.5 Patterns 23113.6 Design Considerations in Castings 23213.7 The Casting Industry 23414 Expendable-Mold Casting Processes 23614.1 Introduction 23614.2 Sand Casting 23614.3 Cores and Core Making 24914.4 Other Expendable-Mold Processes with Multiple- Use Patterns 25214.5 Expendable-Mold Processes Using Single-Use Patterns 25314.6 Shakeout, Cleaning, and Finishing 25914.7 Summary 25915 Multiple-Use-Mold Casting Processes 26015.1 Introduction 26015.2 Permanent-Mold Casting 26015.3 Die Casting 26315.4 Squeeze Casting and Semisolid Casting 26615.5 Centrifugal Casting 26715.6 Continuous Casting 26915.7 Melting 26915.8 Pouring Practice 27115.9 Cleaning, Finishing, Heat Treating, and Inspection 27215.10 Automation in Foundry Operations 27315.11 Process Selection 27316 Powder Metallurgy (Particulate Processing) 27516.1 Introduction 27516.2 The Basic Process 27516.3 Powder Manufacture 27616.4 Powder Testing and Evaluation 27716.5 Powder Mixing and Blending 27716.6 Compacting 27816.7 Sintering 28116.8 Advances in Sintering (Shorter Time, Higher Density, Stronger Products) 28216.9 Hot-Isostatic Pressing 28216.10 Other Techniques to Produce High-Density P/M Products 28316.11 Metal Injection Molding (MIM) 28416.12 Secondary Operations 28516.13 Properties of P/M Products 28716.14 Design of Powder Metallurgy Parts 28816.15 Powder Metallurgy Products 28916.16 Advantages and Disadvantages of Powder Metallurgy 29016.17 Process Summary 29117 Fundamentals of Metal Forming 29217.1 Introduction 29217.2 Forming Processes: Independent Variables 29217.3 Dependent Variables 29317.4 Independent–Dependent Relationships 29417.5 Process Modeling 29517.6 General Parameters 29517.7 Friction, Lubrication, and Wear under Metalworking Conditions 29617.8 Temperature Concerns 29717.9 Formability 30318 Bulk-Forming Processes 30418.1 Introduction 30418.2 Classification of Deformation Processes 30418.3 Bulk Deformation Processes 30418.4 Rolling 30518.5 Forging 30918.6 Extrusion 31818.7 Wire, Rod, and Tube Drawing 32218.8 Cold Forming, Cold Forging, and Impact Extrusion 32418.9 Piercing 32718.10 Other Squeezing Processes 32818.11 Surface Improvement by Deformation Processing 33019 Sheet-Forming Processes 33119.1 Introduction 33119.2 Shearing Operations 33119.3 Bending 33719.4 Drawing and Stretching Processes 34319.5 Alternative Methods of Producing Sheet-Type Products 35319.6 Seamed Pipe Manufacture 35419.7 Presses 35420 Fabrication of Plastics, Ceramics, and Composites 35920.1 Introduction 35920.2 Fabrication of Plastics 35920.3 Processing of Rubber and Elastomers 36920.4 Processing of Ceramics 36920.5 Fabrication of Composite Materials 37221 Fundamentals of Machining/ Orthogonal Machining 38121.1 Introduction 38121.2 Fundamentals 38121.3 Forces and Power in Machining 38621.4 Orthogonal Machining (Two Forces) 39021.5 Chip Thickness Ratio, rc 39421.6 Mechanics of Machining (Statics) 39521.7 Shear Strain, γ, and Shear Front Angle, ϕ 39721.8 Mechanics of Machining (Dynamics) (Section courtsey of Dr. Elliot Stern) 39922 Cutting Tool Materials 40522.1 Cutting Tool Materials 40822.2 Tool Geometry 41722.3 Tool-Coating Processes 41922.4 Tool Failure and Tool Life 42022.5 Taylor Tool Life 42122.6 Cutting Fluids 42522.7 Economics of Machining 42623 Turning and Boring Processes 42823.1 Introduction 42823.2 Fundamentals of Turning, Boring, and Facing Turning 43023.3 Lathe Design and Terminology 43423.4 Cutting Tools for Lathes 43823.5 Workholding in Lathes 44224 Milling 44724.1 Introduction 44724.2 Fundamentals of Milling Processes 44724.3 Milling Tools and Cutters 45324.4 Machines for Milling 45725 Drilling and Related Hole-Making Processes 46225.1 Introduction 46225.2 Fundamentals of the Drilling Process 46325.3 Types of Drills 46425.4 Tool Holders for Drills 47225.5 Workholding for Drilling 47425.6 Machine Tools for Drilling 47525.7 Cutting Fluids for Drilling 47825.8 Counterboring, Countersinking, and Spot Facing 47925.9 Reaming 48026 CNC Processes and Adaptive Control: A(4) and A(5) Levels of Automation 48226.1 Introduction 48226.2 Basic Principles of Numerical Control 48226.3 CNC Part Programming 48826.4 Interpolation and Adaptive Control 49426.5 Machining Center Features and Trends 49726.6 Summary 50127 Sawing, Broaching, Shaping, and Filing Machining Processes 50227.1 Introduction 50227.2 Introduction to Sawing 50227.3 Introduction to Broaching 51027.4 Fundamentals of Broaching 51227.5 Broaching Machines 51627.6 Introduction to Shaping and Planing 51627.7 Introduction to Filing 52028 Abrasive Machining Processes 52328.1 Introduction 52328.2 Abrasives 52428.3 Grinding Wheel Structure and Grade 52828.4 Grinding Wheel Identification 53128.5 Grinding Machines 53428.6 Honing 54028.7 Superfinishing 54228.8 Free Abrasives 54328.9 Design Considerations in Grinding 54729 Nano and Micro-Manufacturing Processes 54829.1 Introduction 54829.2 Lithography 55129.3 Micromachining Processes 55429.4 Deposition Processes 55629.5 How ICs Are Made 56229.6 Nano- and Micro-Scale Metrology 56830 Nontraditional Manufacturing Processes 57030.1 Introduction 57030.2 Chemical Machining Processes 57230.3 Electrochemical Machining Processes 57630.4 Electrical Discharge Machining 58131 Thread and Gear Manufacturing 58931.1 Introduction 58931.2 Thread Making 59231.3 Internal Thread Cutting–Tapping 59531.4 Thread Milling 59731.5 Thread Grinding 59931.6 Thread Rolling 59931.7 Gear Theory and Terminology 60131.8 Gear Types 60331.9 Gear Manufacturing 60431.10 Machining of Gears 60531.12 Gear Finishing 61031.13 Gear Inspection 61132 Surface Integrity and Finishing Processes 61332.1 Introduction 61332.2 Surface Integrity 61332.3 Abrasive Cleaning and Finishing 62032.4 Chemical Cleaning 62432.5 Coatings 62632.6 Vaporized Metal Coatings 63332.7 Clad Materials 63332.8 Textured Surfaces 63332.9 Coil-Coated Sheets 63332.10 Edge Finishing and Burr Removal 63433 Additive Processes—Including 3-D Printing 63733.1 Introduction 63733.2 Layerwise Manufacturing 63833.3 Liquid-Based Processes 64133.4 Powder-Based Processes 64333.5 Deposition-Based Processes 64733.6 Uses and Applications 64933.7 Pros, Cons, and Current and Future Trends 65233.8 Economic Considerations 65534 Manufacturing Automation and Industrial Robots 65634.1 Introduction 65634.2 The A(4) Level of Automation 66034.3 A(5) Level of Automation Requires Evaluation 66634.4 Industrial Robotics 66934.5 Computer-Integrated Manufacturing (CIM) 67534.6 Computer-Aided Design 67734.7 Computer-Aided Manufacturing 67834.8 Summary 67935 Fundamentals of Joining 68035.1 Introduction to Consolidation Processes 68035.2 Classification of Welding and Thermal Cutting Processes 68135.3 Some Common Concerns 68135.4 Types of Fusion Welds and Types of Joints 68135.5 Design Considerations 68235.6 Heat Effects 68435.7 Weldability or Joinability 68835.8 Summary 68936 Gas Flame and Arc Processes 69036.1 Oxyfuel-Gas Welding 69036.2 Oxygen Torch Cutting 69336.3 Flame Straightening 69436.4 Arc Welding 69536.5 Consumable-Electrode Arc Welding 69636.6 Nonconsumable Electrode Arc Welding 70236.7 Other Processes Involving Arcs 70636.8 Arc Cutting 70736.9 Metallurgical and Heat Effects in Thermal Cutting 70936.10 Welding Equipment 71036.11 Thermal Deburring 71137 Resistance and Solid-State Welding Processes 71237.1 Introduction 71237.2 Theory of Resistance Welding 71237.3 Resistance Welding Processes 71437.4 Advantages and Limitations of Resistance Welding 71737.5 Solid-State Welding Processes 71838 Other Welding Processes, Brazing, and Soldering 72638.1 Introduction 72638.2 Other Welding and Cutting Processes 72638.3 Surface Modification by Welding-Related Processes 73238.4 Brazing 73538.5 Soldering 74239 Adhesive Bonding, Mechanical Fastening, and Joining of Nonmetals 74639.1 Adhesive Bonding 74639.2 Mechanical Fastening 75239.3 Joining of Plastics 75539.4 Joining of Ceramics and Glass 75839.5 Joining of Composites 75840 JIG and Fixture Design W 141 The Enterprise (Production System) W 2042 Lean Engineering W 3543 Mixed-Model Final Assembly W 65Index I- 1