Manufacturing Engineering and Technology in SI Units

Serope Kalpakjian isprofessor emeritus of Mechanical and Materials Engineering, the IllinoisInstitute of Technology. He is the author of Mechanical Processing ofMaterials and co-author of Lubricants and Lubrication in MetalworkingOperations (with E.S. Nachtman). The first editions of his textbooks ManufacturingProcesses for Engineering Materials and Manufacturing Engineering andTechnology received the M. Eugene Merchant Manufacturing Textbook Award. Hehas conducted research in various areas of manufacturing, is the author ofnumerous technical papers and articles in handbooks and encyclopedias, and hasedited a number of conference proceedings. He also has been editor andco-editor of several technical journals and has served on various editorialboards, including the Encyclopedia Americana. Among various awards, Professor Kalpakjian has received theForging Industry Educational and Research Foundation Best Paper Award, theExcellence in Teaching Award from lIT, the ASME Centennial Medallion, theInternational Education Award from SME, A Person of the Millennium Award from lIT,the Albert Easton White Outstanding Teacher Award from ASM International, andthe 2016 SME Gold Medal Award. The Outstanding Young Manufacturing EngineerAward of SME, for 2001, was named after him. Professor Kalpakjian is a LifeFellow ASME, Fellow SME, Fellow, and Life Member ASM International, FellowEmeritus International Academy for Production Engineering (CIRP); and he is afounding member and past president of NAMRI. He is a graduate of Robert College(High Honor, Istanbul), Harvard University, and the Massachusetts Institute ofTechnology. Steven R. Schmid isprofessor of Aerospace and Mechanical Engineering, the University of NotreDame, where he teaches and conducts research in the general areas ofmanufacturing, machine design, and tribology. From 2016 to 2018, he served as aProgram Director of the Advanced Manufacturing Program at the National ScienceFoundation. He received his B.S. degree from Illinois Institute of Technology(with Honors) and Master’s and Ph.D. degrees from Northwestern University, allin mechanical engineering. He has received numerous awards, including the JohnT. Parsons Award from SME, the Newkirk Award from ASME, the Kaneb CenterTeaching Award (three times), and the Ruth and Joel Spira Award for Excellencein Teaching. Professor Schmid served as President of the North AmericanManufacturing Research Institution (NAMRI, 2015­–2016) and was appointed thefirst Academic Fellow at the Advanced Manufacturing National Program Office,U.S. Department of Commerce, where he helped design the Manufacturing USAprogram. Dr. Schmid is the author of over 140 technical papers, and hasco-authored Fundamentals of Machine Elements, Fundamentals of FluidFilm Lubrication, Manufacturing Processes for Engineering Materials,and Manufacturing Engineering and Technology. He is a Fellow of theAmerican Society of Mechanical Engineers and the Society of ManufacturingEngineers. He was elected to the Board of the Society of ManufacturingEngineers in 2018.

• General Introduction I.1 What is Manufacturing? I.2 Product Design and Concurrent Engineering I.3 Design for Manufacture, Assembly, Disassembly, and Service I.4 Environmentally Conscious Design, Sustainable Manufacturing,and Product Life Cycle I.5 Selection of Materials I.6 Selection of Manufacturing Processes I.7 Computer-integrated Manufacturing I.8 Quality Assurance and Total Quality Management I.9 Lean Production and Agile Manufacturing I.10 Manufacturing Costs and Global Competition I.11 Trends in Manufacturing PART I: FUNDAMENTALS OF MATERIALS:BEHAVIOR AND MANUFACTURING PROPERTIES 1. The Structure of Metals 1.1 Introduction1.2 Types of Atomic Bonds1.3 The Crystal Structure of Metals1.4 Deformation and Strength of Single Crystals1.5 Grains and Grain Boundaries1.6 Plastic Deformation of Polycrystalline Metals1.7 Recovery, Recrystallization, and Grain Growth 1.8 Cold, Warm, and Hot Working 2. Mechanical Behavior, Testing, and Manufacturing Properties ofMaterials2.1 Introduction 2.2 Tension 2.3 Compression 2.4 Torsion 2.5 Bending (Flexure) 2.6 Hardness 2.7 Fatigue 2.8 Creep 2.9 Impact 2.10 Failure and Fracture of Materials 2.11 Residual Stresses 2.12 Work, Heat, and Temperature 3. Physical Properties of Materials3.1 Introduction 3.2 Density 3.3 Melting Point 3.4 Specific Heat 3.5 Thermal Conductivity 3.6 Thermal Expansion 3.7 Electrical, Magnetic, and Optical Properties 3.8 Corrosion Resistance 4. Metal Alloys: Their Structure and Strengthening by HeatTreatment4.1 Introduction 4.2 Structure of Alloys 4.3 Phase Diagrams 4.4 The Iron-Carbon System 4.5 The Iron—Iron-carbide Phase Diagram and the Development ofMicrostructures in Steels 4.6 Cast Irons 4.7 Heat Treatment of Ferrous Alloys 4.8 Hardenability of Ferrous Alloys 4.9 Heat Treatment of Nonferrous Alloys and Stainless Steels 4.10 Case Hardening 4.11 Annealing 4.12 Heat-treating Furnaces and Equipment 4.13 Design Considerations for Heat Treating 5. Ferrous Metals and Alloys: Production, General Properties, andApplications5.1 Introduction 5.2 Production of Iron and Steel 5.3 Casting of Ingots 5.4 Continuous Casting 5.5 Carbon and Alloy Steels 5.6 Stainless Steels 5.7 Tool and Die Steels6. Nonferrous Metals and Alloys: Production, General Properties,and Applications6.1 Introduction 6.2 Aluminum and Aluminum Alloys 6.3 Magnesium and Magnesium Alloys 6.4 Copper and Copper Alloys 6.5 Nickel and Nickel Alloys 6.6 Superalloys 6.7 Titanium and Titanium Alloys 6.8 Refractory Metals and Alloys 6.9 Beryllium 6.10 Zirconium 6.11 Lithium 6.12 Low-melting Alloys 6.13 Precious Metals 6.14 Shape-memory Alloys (Smart Materials) 6.15 Amorphous Alloys (Metallic Glasses) 6.16 Metal Foams and Metamaterials 6.17 Rare Earth Metals 7. Polymers: Structure, General Properties, and Applications7.1 Introduction 7.2 The Structure of Polymers 7.3 Thermoplastics 7.4 Thermosetting Plastics 7.5 Additives in Plastics 7.6 General Properties and Applications of Thermoplastics 7.7 General Properties and Applications of Thermosetting Plastics 7.8 Biodegradable Plastics 7.9 Elastomers (Rubbers) 8. Ceramics, Glass, Graphite, Diamond, and Nanomaterials:Structure, General Properties, and Applications8.1 Introduction 8.2 The Structure of Ceramics 8.3 General Properties and Applications of Ceramics 8.4 Glasses 8.5 Glass Ceramics 8.6 Graphite 8.7 Diamond 8.8 Nanomaterials 9. Composite Materials: Structure, General Properties, andApplications9.1 Introduction 9.2 The Structure of Reinforced Plastics 9.3 Properties of Reinforced Plastics 9.4 Applications of Reinforced Plastics 9.5 Metal-matrix Composites 9.6 Ceramic-matrix Composites 9.7 Other Composites PART II: METAL-CASTING PROCESSESAND EQUIPMENT10. Fundamentals of Metal Casting 10.1 Introduction 10.2 Solidification of Metals 10.3 Fluid Flow 10.4 Fluidity of Molten Metal 10.5 Heat Transfer 10.6 Defects 11. Metal-casting Processes and Equipment11.1 Introduction 11.2 Expendable-mold, Permanent-pattern Casting Processes 11.3 Expendable-mold, Expendable-pattern Casting Processes 11.4 Permanent-mold Casting Processes 11.5 Casting Techniques for Single-crystal Components 11.6 Rapid Solidification 11.7 Inspection of Castings 11.8 Melting Practice and Furnaces 11.9 Foundries and Foundry Automation 12. Metal Casting: Design, Materials, and Economics12.1 Introduction 12.2 Design Considerations in Casting 12.3 Casting Alloys 12.4 Economics of Casting PART III: FORMING AND SHAPINGPROCESSES AND EQUIPMENT13. Metal-rolling Processes and Equipment 13.1 Introduction 13.2 The Flat-rolling Process 13.3 Flat-rolling Practice 13.4 Rolling Mills 13.5 Various Rolling Processes and Mills 14. Metal-forging Processes and Equipment14.1 Introduction 14.2 Open-die Forging 14.3 Impression-die and Closed-die Forging 14.4 Various Forging Operations 14.5 Forgeability of Metals; Forging Defects 14.6 Die Design, Die Materials, and Lubrication 14.7 Die-manufacturing Methods and Die Failure 14.8 Forging Machines 14.9 Economics of Forging 15. Metal Extrusion and Drawing Processes and Equipment15.1 Introduction 15.2 The Extrusion Process 15.3 Hot Extrusion 15.4 Cold Extrusion 15.5 Extrusion Defects 15.6 Design Considerations 15.7 Extrusion Equipment 15.8 The Drawing Process 15.9 Drawing Practice 15.10 Drawing Defects and Residual Stresses 15.11 Drawing Equipment 16. Sheet-Metal Forming Processes and Equipment16.1 Introduction 16.2 Shearing 16.3 Sheet-metal Characteristics and Formability 16.4 Formability Tests for Sheet Metals 16.5 Bending Sheets, Plates, and Tubes 16.6 Miscellaneous Bending and Related Forming Operations 16.7 Deep Drawing 16.8 Rubber Forming and Hydroforming 16.9 Spinning 16.10 Superplastic Forming 16.11 Hot Stamping 16.12 Specialized Forming Processes 16.13 Manufacturing of Metal Honeycomb Structures 16.14 Design Considerations in Sheet-metal Forming 16.15 Equipment for Sheet-metal Forming 16.16 Economics of Sheet-forming Operations 17. Powder Metal Processes and Equipment17.1 Introduction 17.2 Production of Metal Powders 17.3 Compaction of Metal Powders 17.4 Sintering 17.5 Secondary and Finishing Operations 17.6 Design Considerations 17.7 Economics of Powder Metallurgy 18. Ceramics, Glasses, and Superconductors: Processing andEquipment18.1 Introduction 18.2 Shaping Ceramics 18.3 Forming and Shaping of Glass 18.4 Techniques for Strengthening and Annealing Glass 18.5 Design Considerations for Ceramics and Glasses 18.6 Processing of Superconductors 19. Plastics and Composite Materials: Forming and Shaping19.1 Introduction 19.2 Extrusion 19.3 Injection Molding 19.4 Blow Molding 19.5 Rotational Molding 19.6 Thermoforming 19.7 Compression Molding 19.8 Transfer Molding 19.9 Casting 19.10 Foam Molding 19.11 Cold Forming and Solid-phase Forming 19.12 Processing Elastomers 19.13 Processing Polymer-matrix Composites 19.14 Processing Metal-matrix and Ceramic-matrix Composites 19.15 Design Considerations 19.16 Economics of Processing Plastics and Composite Materials  20. Additive Manufacturing 20.1 Introduction 20.2 Additive Manufacturing Methodology 20.3 Extrusion-based Processes 20.4 Photopolymerization 20.5 Material Jetting 20.6 Powder Bed Processes 20.7 Laminated-object Manufacturing 20.8 Miscellaneous Processes 20.9 Emerging AM Applications 20.10 Direct Manufacturing and Rapid Tooling 20.11 Design for Additive Manufacturing 20.12 Additive Manufacturing Economics    PART IV: MACHINING PROCESSES ANDMACHINE TOOLS 21. Fundamentals of Machining 21.1 Introduction 21.2 Mechanics of Cutting 21.3 Cutting Forces and Power 21.4 Temperatures in Cutting 21.5 Tool Life: Wear and Failure 21.6 Surface Finish and Integrity 21.7 Machinability 22. Cutting-Tool Materials and Cutting Fluids22.1 Introduction 22.2 High-speed Steels 22.3 Cast-cobalt Alloys 22.4 Carbides 22.5 Coated Tools 22.6 Alumina-based Ceramics 22.7 Cubic Boron Nitride 22.8 Silicon-Nitride-based Ceramics 22.9 Diamond 22.10 Whisker-reinforced Materials and Nanomaterials 22.11 Tool Costs and Reconditioning of Tools 22.12 Cutting Fluids 23. Machining Processes: Turning and Hole Making23.1 Introduction 23.2 The Turning Process 23.3 Lathes and Lathe Operations 23.4 Boring and Boring Machines 23.5 Drilling, Drills, and Drilling Machines 23.6 Reaming and Reamers 23.7 Tapping and Taps 24. Machining Processes: Milling, Broaching, Sawing, Filing, andGear Manufacturing24.1 Introduction 24.2 Milling and Milling Machines 24.3 Planing and Shaping 24.4 Broaching and Broaching Machines 24.5 Sawing 24.6 Filing 24.7 Gear Manufacturing by Machining25. Machining Centers, Machine-tool Structures, and MachiningEconomics25.1 Introduction 25.2 Machining Centers 25.3 Machine-tool Structures 25.4 Vibration and Chatter in Machining Operations 25.5 High-speed Machining 25.6 Hard Machining 25.7 Ultraprecision Machining 25.8 Machining Economics 26. Abrasive Machining and Finishing Operations26.1 Introduction 26.2 Abrasives and Bonded Abrasives 26.3 The Grinding Process 26.4 Grinding Operations and Machines 26.5 Design Considerations for Grinding 26.6 Ultrasonic Machining 26.7 Finishing Operations 26.8 Deburring Operations 26.9 Economics of Abrasive Machining and Finishing Operations 27. Advanced Machining Processes27.1 Introduction 27.2 Chemical Machining 27.3 Electrochemical Machining 27.4 Electrochemical Grinding 27.5 Electrical-discharge Machining 27.6 Laser-beam Machining 27.7 Electron-beam Machining 27.8 Water-jet Machining 27.9 Abrasive-jet Machining 27.10 Hybrid Machining Systems 27.11 Economics of Advanced Machining Processes PART V: MICROMANUFACTURING ANDFABRICATION OF MICROELECTRONIC DEVICES28. Fabrication of Microelectronic Devices 28.1 Introduction 28.2 Clean Rooms 28.3 Semiconductors and Silicon 28.4 Crystal Growing and Wafer Preparation 28.5 Film Deposition 28.6 Oxidation 28.7 Lithography 28.8 Etching 28.9 Diffusion and Ion Implantation 28.10 Metallization and Testing 28.11 Wire Bonding and Packaging 28.12 Yield and Reliability 28.13 Printed Circuit Boards 28.14 Roll-to-Roll Printing of Flexible Electronics 28.15 Flexible Hybrid Electronics 29. Fabrication of Microelectromechanical Devices and Systems andNanoscale Manufacturing29.1 Introduction 29.2 Micromachining of MEMS Devices 29.3 Electroforming-based Processes 29.4 Solid Free-form Fabrication of Devices 29.5 Mesoscale Manufacturing 29.6 Nanoscale Manufacturing PART VI: JOINING PROCESSES ANDEQUIPMENT30. Fusion Welding Processes 30.1 Introduction 30.2 Oxyfuel–Gas Welding 30.3 Arc-welding Processes: Nonconsumable Electrode 30.4 Arc-welding Processes: Consumable Electrode 30.5 Electrodes for Arc Welding 30.6 Electron-beam Welding 30.7 Laser-beam Welding 30.8 Cutting 30.9 The Weld Joint, Quality, and Testing 30.10 Joint Design and Process Selection 31. Solid-State Welding Processes31.1 Introduction 31.2 Cold Welding and Roll Bonding 31.3 Ultrasonic Welding 31.4 Friction Welding 31.5 Resistance Welding 31.6 Explosion Welding 31.7 Diffusion Bonding 31.8 Economics of Welding Operations 32. Brazing, Soldering, Adhesive-bonding, and Mechanical FasteningProcesses32.1 Introduction 32.2 Brazing 32.3 Soldering 32.4 Adhesive Bonding 32.5 Mechanical Fastening 32.6 Joining Plastics, Ceramics, and Glasses 32.7 Economics of Joining Operations PART VII: SURFACE TECHNOLOGY33. Surface Roughness and Measurement; Friction, Wear, andLubrication 33.1 Introduction 33.2 Surface Structure and Integrity 33.3 Surface Texture and Roughness 33.4 Friction 33.5 Wear 33.6 Lubrication 33.7 Metalworking Fluids and Their Selection 34. Surface Treatments, Coatings, and Cleaning34.1 Introduction 34.2 Mechanical Surface Treatments 34.3 Mechanical Plating and Cladding 34.4 Case Hardening and Hard Facing 34.5 Thermal Spraying 34.6 Vapor Deposition 34.7 Ion Implantation and Diffusion Coating 34.8 Laser Treatments 34.9 Electroplating, Electroless Plating, and Electroforming 34.10 Conversion Coatings 34.11 Hot Dipping 34.12 Porcelain Enameling; Ceramic and Organic Coatings 34.13 Diamond Coating and Diamondlike Carbon 34.14 Surface Texturing 34.15 Painting 34.16 Cleaning of Surfaces PART VIII: ENGINEERING METROLOGY,INSTRUMENTATION, AND QUALITY ASSURANCE35. Surface Treatments, Coatings, and Cleaning 35.1 Introduction 35.2 Measurement Standards 35.3 Geometric Features of Parts: Analog and Digital Measurements 35.4 Traditional Measuring Methods and Instruments 35.5 Modern Measuring Instruments and Machines 35.6 Automated Measurement 35.7 General Characteristics and Selection of MeasuringInstruments 35.8 Geometric Dimensioning and Tolerancing 36. Quality Assurance, Testing, and Inspection36.1 Introduction 36.2 Product Quality 36.3 Quality Assurance 36.4 Total Quality Management 36.5 Taguchi Methods 36.6 The ISO and QS Standards 36.7 Statistical Methods of Quality Control 36.8 Statistical Process Control 36.9 Reliability of Products and Processes 36.10 Nondestructive Testing 36.11 Destructive Testing 36.12 Automated Inspection PART IX: MANUFACTURING IN ACOMPETITIVE ENVIRONMENT37. Automation of Manufacturing Processes and Operations 37.1 Introduction 37.2 Automation 37.3 Numerical Control 37.4 Adaptive Control 37.5 Material Handling and Movement 37.6 Industrial Robots 37.7 Sensor Technology 37.8 Flexible Fixturing 37.9 Assembly Systems 37.10 Design Considerations for Fixturing, Assembly, Disassembly,and Servicing 37.11 Economic Considerations 38. Computer-aided Manufacturing38.1 Introduction 38.2 Manufacturing Systems 38.3 Computer-integrated Manufacturing 38.4 Computer-aided Design and Engineering 38.5 Computer-aided Manufacturing 38.6 Computer-aided Process Planning 38.7 Computer Simulation of Manufacturing Processes and Systems 38.8 Group Technology 39. Computer-integrated Manufacturing Systems39.1 Introduction 39.2 Cellular Manufacturing 39.3 Flexible Manufacturing Systems 39.4 Mass Customization 39.5 Holonic Manufacturing 39.6 Just-in-time Production 39.7 Lean Manufacturing 39.8 Communications Networks in Manufacturing 39.9 Artificial Intelligence and Machine Learning 39.10 Economic Considerations 40. Product Design and Manufacturing in a Competitive Environment40.1 Introduction 40.2 Product Design 40.3 Product Quality 40.4 Life-cycle Assessment and Sustainable Manufacturing 40.5 Energy Consumption in Manufacturing 40.6 Material Selection for Products 40.7 Material Substitution 40.8 Manufacturing Process Capabilities 40.9 Process Selection 40.10 ManufacturingCosts and Cost Reduction