Manufacturing engineering and technology /
Kalpakjian, Serope, 1928-
Manufacturing engineering and technology / Serope Kalpakjian, Steven R. Schmid. - sixth edition - xxiv, 1176 pages : illustrations ; 26 cm.
Includes bibliographical references and index.
General Introduction 1I.1 What Is Manufacturing? 1I.2 Product Design and Concurrent Engineering 8I.3 Design for Manufacture, Assembly, Disassembly, and Service 11I.4 Green Design and Manufacturing 13I.5 Selection of Materials 15I.6 Selection of Manufacturing Processes 18I.7 Computer-integrated Manufacturing 26I.8 Quality Assurance and Total Quality Management 29I.9 Lean Production and Agile Manufacturing 32I.10 Manufacturing Costs and Global Competition 32I.11 General Trends in Manufacturing 34 Part I: Fundamentals of Materials: Their Behaviorand Manufacturing Properties 371 The Structure of Metals 401.1 Introduction 401.2 Types of Atomic Bonds 411.3 The Crystal Structure of Metals 421.4 Deformation and Strength of Single Crystals 441.5 Grains and Grain Boundaries 471.6 Plastic Deformation of Polycrystalline Metals 501.7 Recovery, Recrystallization, and Grain Growth 511.8 Cold, Warm, and Hot Working 52Summary 53 Key Terms 53 Bibliography 54Review Questions 54 Qualitative Problems 54Quantitative Problems 55 Synthesis, Design, and Projects 55 2 Mechanical Behavior, Testing, andManufacturing Properties of Materials 562.1 Introduction 562.2 Tension 572.3 Compression 662.4 Torsion 672.5 Bending (Flexure) 682.6 Hardness 682.7 Fatigue 742.8 Creep 752.9 Impact 752.10 Failure and Fracture of Materials in Manufacturingand in Service 762.11 Residual Stresses 812.12 Work, Heat, and Temperature 82Summary 83 Key Terms 84 Bibliography 84Review Questions 84 Qualitative Problems 85Quantitative Problems 85 Synthesis, Design, and Projects 86 3 Physical Properties of Materials 883.1 Introduction 883.2 Density 893.3 Melting Point 923.4 Specific Heat 923.5 Thermal Conductivity 933.6 Thermal Expansion 933.7 Electrical, Magnetic, and Optical Properties 943.8 Corrosion Resistance 95Summary 97 Key Terms 97 Bibliography 98Review Questions 98 Qualitative Problems 98Quantitative Problems 98 Synthesis, Design, and Projects 99 4 Metal Alloys: Their Structure and Strengtheningby Heat Treatment 1004.1 Introduction 1004.2 Structure of Alloys 1014.3 Phase Diagrams 1034.4 The Iron-Carbon System 1074.5 The Iron-Iron-carbide Phase Diagram and the Developmentof Microstructures in Steels 1084.6 Cast Irons 1104.7 Heat Treatment of Ferrous Alloys 1114.8 Hardenability of Ferrous Alloys 1154.9 Heat Treatment of Nonferrous Alloys andStainless Steels 1174.10 Case Hardening 1194.11 Annealing 1214.12 Heat-treating Furnaces and Equipment 1234.13 Design Considerations for Heat Treating 125Summary 126 Key Terms 127 Bibliography 127Review Questions 127 Qualitative Problems 127Quantitative Problems 128 Synthesis, Design, and Projects 128 5 Ferrous Metals and Alloys: Production, GeneralProperties, and Applications 1295.1 Introduction 1295.2 Production of Iron and Steel 1305.3 Casting of Ingots 1335.4 Continuous Casting 1345.5 Carbon and Alloy Steels 1365.6 Stainless Steels 1435.7 Tool and Die Steels 145Summary 147 Key Terms 148 Bibliography 148Review Questions 148 Qualitative Problems 149Quantitative Problems 149 Synthesis, Design, and Projects 150 6 Nonferrous Metals and Alloys: Production,General Properties, and Applications 1516.1 Introduction 1516.2 Aluminum and Aluminum Alloys 1526.3 Magnesium and Magnesium Alloys 1576.4 Copper and Copper Alloys 1586.5 Nickel and Nickel Alloys 1606.6 Superalloys 1616.7 Titanium and Titanium Alloys 1626.8 Refractory Metals and Alloys 1636.9 Beryllium 1646.10 Zirconium 1646.11 Low-melting Alloys 1646.12 Precious Metals 1666.13 Shape-memory Alloys (Smart Materials) 1666.14 Amorphous Alloys (Metallic Glasses) 1676.15 Metal Foams 167Summary 168 Key Terms 168 Bibliography 169Review Questions 169 Qualitative Problems 169Quantitative Problems 170 Synthesis, Design, and Projects 170 7 Polymers: Structure, General Properties,and Applications 1717.1 Introduction 1717.2 The Structure of Polymers 1737.3 Thermoplastics 1807.4 Thermosetting Plastics 1847.5 Additives in Plastics 1847.6 General Properties and Applications of Thermoplastics 1857.7 General Properties and Applications of ThermosettingPlastics 1887.8 Biodegradable Plastics 1907.9 Elastomers (Rubbers) 191Summary 192 Key Terms 193 Bibliography 193Review Questions 194 Qualitative Problems 194Quantitative Problems 195 Synthesis, Design, and Projects 195 8 Ceramics, Graphite, Diamond, andNanomaterials: Structure, General Properties,and Applications 1968.1 Introduction 1968.2 The Structure of Ceramics 1978.3 General Properties and Applications of Ceramics 2018.4 Glasses 2058.5 Glass Ceramics 2078.6 Graphite 2088.7 Diamond 2108.8 Nanomaterials 210Summary 212 Key Terms 212 Bibliography 213Review Questions 213 Qualitative Problems 214Quantitative Problems 214 Synthesis, Design, and Projects 214 9 Composite Materials: Structure, GeneralProperties, and Applications 2169.1 Introduction 2169.2 The Structure of Reinforced Plastics 2179.3 Properties of Reinforced Plastics 2229.4 Applications of Reinforced Plastics 2259.5 Metal-matrix Composites 2279.6 Ceramic-matrix Composites 2299.7 Other Composites 230Summary 231 Key Terms 231 Bibliography 231Review Questions 232 Qualitative Problems 232Quantitative Problems 233 Synthesis, Design, and Projects 233 Part II: Metal-Casting Processesand Equipment 235 10 Fundamentals of Metal Casting 23710.1 Introduction 23710.2 Solidification of Metals 23810.3 Fluid Flow 24310.4 Fluidity of Molten Metal 24510.5 Heat Transfer 24710.6 Defects 249Summary 253 Key Terms 254 Bibliography 254Review Questions 254 Qualitative Problems 255Quantitative Problems 255 Synthesis, Design, and Projects 256 11 Metal-Casting Processes and Equipment 25811.1 Introduction 25811.2 Expendable-mold, Permanent-pattern Casting Processes 26211.3 Expendable-mold, Expendable-pattern Casting Processes 27011.4 Permanent-mold Casting Processes 27711.5 Casting Techniques for Single-crystal Components 28511.6 Rapid Solidification 28611.7 Inspection of Castings 28711.8 Melting Practice and Furnaces 28711.9 Foundries and Foundry Automation 289Summary 289 Key Terms 290 Bibliography 290Review Questions 291 Qualitative Problems 291Quantitative Problems 292 Synthesis, Design, and Projects 292 12 Metal Casting: Design, Materials,and Economics 29412.1 Introduction 29412.2 Design Considerations in Casting 29412.3 Casting Alloys 30212.4 Economics of Casting 307Summary 308 Key Terms 309 Bibliography 309Review Questions 309 Qualitative Problems 309Quantitative Problems 310 Synthesis, Design, and Projects 310 Part III: Forming and Shaping Processesand Equipment 313 13 Metal-Rolling Processes and Equipment 31613.1 Introduction 31613.2 The Flat-rolling Process 31813.3 Flat-rolling Practice 32213.4 Rolling Mills 32513.5 Various Rolling Processes and Mills 327Summary 332 Key Terms 333 Bibliography 333Review Questions 333 Qualitative Problems 333Quantitative Problems 334 Synthesis, Design, and Projects 334 14 Metal-Forging Processes and Equipment 33514.1 Introduction 33514.2 Open-die Forging 33714.3 Impression-die and Closed-die Forging 33914.4 Various Forging Operations 34314.5 Forgeability of Metals; Forging Defects 34814.6 Die Design, Die Materials, and Lubrication 34914.7 Die-manufacturing Methods and Die Failures 35114.8 Forging Machines 35314.9 Economics of Forging 355Summary 357 Key Terms 358 Bibliography 358Review Questions 358 Qualitative Problems 358Quantitative Problems 359 Synthesis, Design, and Projects 359 15 Metal Extrusion and Drawing Processesand Equipment 36015.1 Introduction 36015.2 The Extrusion Process 36215.3 Hot Extrusion 36415.4 Cold Extrusion 36815.5 Extrusion Defects 37115.6 Extrusion Equipment 37315.7 The Drawing Process 37315.8 Drawing Practice 37515.9 Drawing Defects and Residual Stresses 37715.10 Drawing Equipment 377Summary 378 Key Terms 378 Bibliography 379Review Questions 379 Qualitative Problems 379Quantitative Problems 380 Synthesis, Design, and Projects 380 16 Sheet-Metal Forming Processes andEquipment 38116.1 Introduction 38116.2 Shearing 38216.3 Sheet-metal Characteristics and Formability 39216.4 Formability Tests for Sheet Metals 39416.5 Bending Sheets, Plates, and Tubes 39716.6 Miscellaneous Bending and Related Operations 40116.7 Deep Drawing 40716.8 Rubber Forming and Hydroforming 41316.9 Spinning 41716.10 Superplastic Forming 42016.11 Specialized Forming Processes 42116.12 Manufacturing of Metal Honeycomb Structures 42616.13 Design Considerations in Sheet-metal Forming 42816.14 Equipment for Sheet-metal Forming 43016.15 Economics of Sheet-forming Operations 431Summary 432 Key Terms 433 Bibliography 433Review Questions 434 Qualitative Problems 434Quantitative Problems 435 Synthesis, Design, and Projects 435 17 Powder-Metal Processing and Equipment 43717.1 Introduction 43717.2 Production of Metal Powders 43817.3 Compaction of Metal Powders 44417.4 Sintering 45217.5 Secondary and Finishing Operations 45617.6 Design Considerations 45717.7 Process Capabilities 45917.8 Economics of Powder Metallurgy 460Summary 462 Key Terms 462 Bibliography 463Review Questions 463 Qualitative Problems 463Quantitative Problems 464 Synthesis, Design, and Projects 464 18 Ceramics, Glasses, and Superconductors:Processing and Equipment 46518.1 Introduction 46518.2 Shaping Ceramics 46618.3 Forming and Shaping of Glass 47218.4 Techniques for Strengthening and Annealing Glass 47618.5 Design Considerations for Ceramics and Glasses 47818.6 Processing of Superconductors 479Summary 480 Key Terms 481 Bibliography 481Review Questions 482 Qualitative Problems 482Quantitative Problems 482 Synthesis, Design, and Projects 483 19 Plastics and Composite Materials: Formingand Shaping 48419.1 Introduction 48419.2 Extrusion 48619.3 Injection Molding 49319.4 Blow Molding 49919.5 Rotational Molding 50119.6 Thermoforming 50219.7 Compression Molding 50319.8 Transfer Molding 50419.9 Casting 50519.10 Foam Molding 50619.11 Cold Forming and Solid-phase Forming 50719.12 Processing Elastomers 50719.13 Processing Polymer-matrix Composites 50819.14 Processing Metal-matrix and Ceramic-matrix Composites 51719.15 Design Considerations 51819.16 Economics of Processing Plastics and Composite Materials 520Summary 521 Key Terms 522 Bibliography 522Review Questions 523 Qualitative Problems 523Quantitative Problems 524 Synthesis, Design, and Projects 524 20 Rapid-Prototyping Processes andOperations 52520.1 Introduction 52520.2 Subtractive Processes 52820.3 Additive Processes 53020.4 Virtual Prototyping 54120.5 Direct Manufacturing and Rapid Tooling 542Summary 549 Key Terms 549 Bibliography 549Review Questions 550 Qualitative Problems 550Quantitative Problems 550 Synthesis, Design, and Projects 551 Part IV: Machining Processesand Machine Tools 553 21 Fundamentals of Machining 55621.1 Introduction 55621.2 Mechanics of Cutting 55821.3 Cutting Forces and Power 56821.4 Temperatures in Cutting 57121.5 Tool Life: Wear and Failure 57421.6 Surface Finish and Integrity 58121.7 Machinability 583Summary 587 Key Terms 588 Bibliography 588Review Questions 588 Qualitative Problems 589Quantitative Problems 589 Synthesis, Design, and Projects 590 22 Cutting-Tool Materials and Cutting Fluids 59122.1 Introduction 59122.2 High-speed Steels 59522.3 Cast-cobalt Alloys 59622.4 Carbides 59622.5 Coated Tools 60022.6 Alumina-based Ceramics 60422.7 Cubic Boron Nitride 60522.8 Silicon-nitride-based Ceramics 60522.9 Diamond 60522.10 Whisker-reinforced Materials and Nanomaterials 60622.11 Tool Costs and Reconditioning of Tools 60722.12 Cutting Fluids 607Summary 612 Key Terms 612 Bibliography 613Review Questions 613 Qualitative Problems 613Quantitative Problems 614 Synthesis, Design, and Projects 614 23 Machining Processes: Turning and HoleMaking 61523.1 Introduction 61523.2 The Turning Process 61823.3 Lathes and Lathe Operations 62623.4 Boring and Boring Machines 64123.5 Drilling, Drills, and Drilling Machines 64323.6 Reaming and Reamers 65223.7 Tapping and Taps 653Summary 655 Key Terms 656 Bibliography 656Review Questions 656 Qualitative Problems 657Quantitative Problems 657 Synthesis, Design, and Projects 658 24 Machining Processes: Milling, Broaching, Sawing,Filing, and Gear Manufacturing 65924.1 Introduction 65924.2 Milling and Milling Machines 66024.3 Planing and Shaping 67424.4 Broaching and Broaching Machines 67524.5 Sawing 67824.6 Filing 68124.7 Gear Manufacturing by Machining 681Summary 689 Key Terms 690 Bibliography 690Review Questions 690 Qualitative Problems 691Quantitative Problems 691 Synthesis, Design, and Projects 692 25 Machining Centers, Machine-Tool Structures,and Machining Economics 69325.1 Introduction 69325.2 Machining Centers 69425.3 Machine-tool Structures 70225.4 Vibration and Chatter in Machining Operations 70625.5 High-speed Machining 70925.6 Hard Machining 71125.7 Ultraprecision Machining 71125.8 Machining Economics 713Summary 717 Key Terms 717 Bibliography 717Review Questions 717 Qualitative Problems 718Quantitative Problems 718 Synthesis, Design, and Projects 718 26 Abrasive Machining and FinishingOperations 71926.1 Introduction 71926.2 Abrasives and Bonded Abrasives 72126.3 The Grinding Process 72726.4 Grinding Operations and Machines 73626.5 Design Considerations for Grinding 74426.6 Ultrasonic Machining 74426.7 Finishing Operations 74626.8 Deburring Operations 75026.9 Economics of Abrasive Machining and Finishing Operations 753Summary 754 Key Terms 755 Bibliography 755Review Questions 756 Qualitative Problems 756Quantitative Problems 757 Synthesis, Design, and Projects 757 27 Advanced Machining Processes 75927.1 Introduction 75927.2 Chemical Machining 76127.3 Electrochemical Machining 76527.4 Electrochemical Grinding 76827.5 Electrical-discharge Machining 76927.6 Laser-beam Machining 77427.7 Electron-beam Machining 77727.8 Water-jet Machining 77827.9 Abrasive-jet Machining 77927.10 Hybrid Machining Systems 78027.11 Economics of Advanced Machining Processes 781Summary 784 Key Terms 784 Bibliography 784Review Questions 785 Qualitative Problems 785Quantitative Problems 785 Synthesis, Design, and Projects 786 Part V: Micromanufacturing and Fabrication ofMicroelectronic Devices 787 28 Fabrication of Microelectronic Devices 79028.1 Introduction 79028.2 Clean Rooms 79328.3 Semiconductors and Silicon 79428.4 Crystal Growing and Wafer Preparation 79528.5 Film Deposition 79828.6 Oxidation 79928.7 Lithography 80028.8 Etching 80828.9 Diffusion and Ion Implantation 81628.10 Metallization and Testing 81828.11 Wire Bonding and Packaging 82028.12 Yield and Reliability 82528.13 Printed Circuit Boards 826Summary 827 Key Terms 828 Bibliography 828Review Questions 829 Qualitative Problems 829Quantitative Problems 830 Synthesis, Design, and Projects 830 29 Fabrication of Microelectromechanical Devicesand Systems and Nanoscale Manufacturing 83129.1 Introduction 83129.2 Micromachining of MEMS Devices 83329.3 The LIGA Microfabrication Process 84429.4 Solid Free-form Fabrication of Devices 85029.5 Nanoscale Manufacturing 855Summary 858 Key Terms 858 Bibliography 858Review Questions 859 Qualitative Problems 859Quantitative Problems 860 Synthesis, Design, and Projects 860 Part VI: Joining Processes andEquipment 861 30 Fusion-Welding Processes 86530.1 Introduction 86530.2 Oxyfuel-gas Welding 86630.3 Arc-welding Processes: Nonconsumable Electrode 86930.4 Arc-welding Processes: Consumable Electrode 87330.5 Electrodes for Arc Welding 87930.6 Electron-beam Welding 88030.7 Laser-beam Welding 88030.8 Cutting 88230.9 The Weld Joint, Quality, and Testing 88430.10 Joint Design and Process Selection 893Summary 897 Key Terms 897 Bibliography 898Review Questions 898 Qualitative Problems 898Quantitative Problems 899 Synthesis, Design, and Projects 899 31 Solid-State Welding Processes 90031.1 Introduction 90031.2 Cold Welding and Roll Bonding 90131.3 Ultrasonic Welding 90231.4 Friction Welding 90331.5 Resistance Welding 90531.6 Explosion Welding 91331.7 Diffusion Bonding 91431.8 Economics of Welding Operations 916Summary 918 Key Terms 919 Bibliography 919Review Questions 919 Qualitative Problems 919Quantitative Problems 920 Synthesis, Design, and Projects 920 32 Brazing, Soldering, Adhesive-Bonding,and Mechanical-Fastening Processes 92132.1 Introduction 92132.2 Brazing 92232.3 Soldering 92632.4 Adhesive Bonding 93132.5 Mechanical Fastening 93932.6 Joining Plastics, Ceramics, and Glasses 94232.7 Economics of Joining Operations 945Summary 946 Key Terms 947 Bibliography 947Review Questions 947 Qualitative Problems 948Quantitative Problems 948 Synthesis, Design, and Projects 948 Part VII: Surface Technology 949 33 Surface Roughness and Measurement; Friction,Wear, and Lubrication 95133.1 Introduction 95133.2 Surface Structure and Integrity 95233.3 Surface Texture and Roughness 95333.4 Friction 95733.5 Wear 96133.6 Lubrication 96433.7 Metalworking Fluids and Their Selection 966Summary 970 Key Terms 970 Bibliography 971Review Questions 971 Qualitative Problems 971Quantitative Problems 972 Synthesis, Design, and Projects 972 34 Surface Treatments, Coatings, and Cleaning 97334.1 Introduction 97334.2 Mechanical Surface Treatments 97434.3 Mechanical Plating and Cladding 97634.4 Case Hardening and Hard Facing 97634.5 Thermal Spraying 97734.6 Vapor Deposition 97934.7 Ion Implantation and Diffusion Coating 98234.8 Laser Treatments 98234.9 Electroplating, Electroless Plating, and Electroforming 98334.10 Conversion Coatings 98634.11 Hot Dipping 98734.12 Porcelain Enameling; Ceramic and Organic Coatings 98834.13 Diamond Coating and Diamondlike Carbon 98934.14 Surface Texturing 99034.15 Painting 99034.16 Cleaning of Surfaces 991Summary 993 Key Terms 993 Bibliography 993Review Questions 994 Qualitative Problems 994Quantitative Problems 994 Synthesis, Design, and Projects 995 Part VIII: Engineering Metrology,Instrumentation, and QualityAssurance 997 35 Engineering Metrology andInstrumentation 99835.1 Introduction 99835.2 Measurement Standards 99935.3 Geometric Features of Parts; Analog and DigitalMeasurements 100035.4 Traditional Measuring Methods and Instruments 100135.5 Modern Measuring Instruments and Machines 100835.6 Automated Measurement and Inspection 101135.7 General Characteristics and Selection of MeasuringInstruments 101235.8 Geometric Dimensioning and Tolerancing 1012Summary 1017 Key Terms 1017 Bibliography 1017Review Questions 1018 Qualitative Problems 1018Quantitative Problems 1018 Synthesis, Design, and Projects 1019 36 Quality Assurance, Testing, and Inspection 102036.1 Introduction 102036.2 Product Quality 102136.3 Quality Assurance 102236.4 Total Quality Management 102336.5 Taguchi Methods 102536.6 The ISO and QS Standards 102936.7 Statistical Methods of Quality Control 103036.8 Statistical Process Control 103336.9 Reliability of Products and Processes 103936.10 Nondestructive Testing 104036.11 Destructive Testing 104436.12 Automated Inspection 1044Summary 1045 Key Terms 1045 Bibliography 1046Review Questions 1046 Qualitative Problems 1047Quantitative Problems 1047 Synthesis, Design, and Projects 1047 Part IX: Manufacturing in a CompetitiveEnvironment 1049 37Automation of Manufacturing Processes 105137.1 Introduction 105137.2 Automation 105337.3 Numerical Control 106037.4 Adaptive Control 106637.5 Material Handling and Movement 106837.6 Industrial Robots 107137.7 Sensor Technology 107737.8 Flexible Fixturing 108137.9 Assembly Systems 108337.10 Design Considerations for Fixturing, Assembly, Disassembly,and Servicing 108637.11 Economic Considerations 1089Summary 1089 Key Terms 1090 Bibliography 1090Review Questions 1091 Qualitative Problems 1091Quantitative Problems 1092 Synthesis, Design, and Projects 1092 38 Computer-Aided Manufacturing 109338.1 Introduction 109338.2 Manufacturing Systems 109438.3 Computer-integrated Manufacturing 109438.4 Computer-aided Design and Engineering 109738.5 Computer-aided Manufacturing 110438.6 Computer-aided Process Planning 110438.7 Computer Simulation of Manufacturing Processesand Systems 110738.8 Group Technology 1108Summary 1115 Key Terms 1115 Bibliography 1115Review Questions 1116 Qualitative Problems 1116Synthesis, Design, and Projects 1116 39 Computer-Integrated ManufacturingSystems 111739.1 Introduction 111739.2 Cellular Manufacturing 111839.3 Flexible Manufacturing Systems 112039.4 Holonic Manufacturing 112239.5 Just-in-time Production 112439.6 Lean Manufacturing 112539.7 Communications Networks in Manufacturing 112739.8 Artificial Intelligence 112939.9 Economic Considerations 1132Summary 1132 Key Terms 1133 Bibliography 1133Review Questions 1134 Qualitative Problems 1134Synthesis, Design, and Projects 1134 40 Product Design and Process Selectionin a Competitive Environment 113540.1 Introduction 113540.2 Product Design 113640.3 Product Quality and Life Expectancy 113940.4 Life-cycle Assessment and Sustainable Manufacturing 114040.5 Material Selection for Products 114240.6 Material Substitution 114640.7 Manufacturing Process Capabilities 114840.8 Process Selection 115240.9 Manufacturing Costs and Cost Reduction 1156Summary 1161 Key Terms 1161 Bibliography 1162Review Questions 1162 Qualitative Problems 1162Synthesis, Design, and Projects 1163Index 1165 Case Studies11.1: Lost-foam Casting of Engine Blocks 27211.2: Investment Casting of Total Knee Replacements 27514.1: Manufacture of a Stepped Pin by Heading and PiercingOperations 34514.2: Suspension Components for the Lotus Elise Automobile 35616.1: Manufacturing of Food and Beverage Cans 41216.2: Tube Hydroforming of an Automotive Radiator Closure 41516.3: Cymbal Manufacture 42417.1: Powder Metallurgy Parts in a Snowblower 46118.1: Production of High-temperature Superconducting Tapes 48019.1: Manufacture of Head Protector (TM) Tennis Racquets 51520.1: Invisalign (R) Orthodontic Aligners 54323.1: Bone Screw Retainer 65424.1: Ping Golf Putter 68827.1: Electrochemical Machining of a Biomedical Implant 76727.2: Manufacture of Small Satellites 78129.1: Digital Micromirror Device 83729.2: Accelerometer for Automotive Air Bags 85131.1: Friction Welding of Pistons 91732.1: Light Curing Acrylic Adhesives for Medical Products 93736.1: Manufacture of Television Sets by Sony Corporation 102836.2: Dimensional Control of Plastic Parts in Saturn Automobiles 103837.1: Robotic Deburring of a Blow-molded Toboggan 107638.1: CAD Model Development for Automotive Components 110140.1: Automobile Tires: From Cradle-to-grave to Cradle-to-cradle 1141
Manufacturing Engineering & Technology, 6/e, presents a mostly qualitative description of the science, technology, and practice of manufacturing. This includes detailed descriptions of manufacturing processes and the manufacturing enterprise that will help introduce students to important concepts.
With a total of 120 examples and case studies, up-to-date and comprehensive coverage of all topics, and superior two-color graphics, this text provides a solid background for manufacturing students and serves as a valuable reference text for professionals.
The Sixth Edition has been completely updated, and addresses issues essential to modern manufacturing, ranging from traditional topics such as casting, forming, machining, and joining, to advanced topics such as the fabrication of microelectronic devices and microelectromechanical systems (MEMS), and nanomaterials and nanomanufacturing.
With each purchase of a new copy of the Sixth Edition, students receive access to Video Solutions and myeBook, Pearson's new visual tools for teaching and reinforcing key concepts and techniques.
9780136081685 0136081681 9780136081692 (hbk.) 013608169X (hbk.) 9810681445 9789810681449
Production engineering.
Manufacturing processes.
670.42 / K.S.M
Manufacturing engineering and technology / Serope Kalpakjian, Steven R. Schmid. - sixth edition - xxiv, 1176 pages : illustrations ; 26 cm.
Includes bibliographical references and index.
General Introduction 1I.1 What Is Manufacturing? 1I.2 Product Design and Concurrent Engineering 8I.3 Design for Manufacture, Assembly, Disassembly, and Service 11I.4 Green Design and Manufacturing 13I.5 Selection of Materials 15I.6 Selection of Manufacturing Processes 18I.7 Computer-integrated Manufacturing 26I.8 Quality Assurance and Total Quality Management 29I.9 Lean Production and Agile Manufacturing 32I.10 Manufacturing Costs and Global Competition 32I.11 General Trends in Manufacturing 34 Part I: Fundamentals of Materials: Their Behaviorand Manufacturing Properties 371 The Structure of Metals 401.1 Introduction 401.2 Types of Atomic Bonds 411.3 The Crystal Structure of Metals 421.4 Deformation and Strength of Single Crystals 441.5 Grains and Grain Boundaries 471.6 Plastic Deformation of Polycrystalline Metals 501.7 Recovery, Recrystallization, and Grain Growth 511.8 Cold, Warm, and Hot Working 52Summary 53 Key Terms 53 Bibliography 54Review Questions 54 Qualitative Problems 54Quantitative Problems 55 Synthesis, Design, and Projects 55 2 Mechanical Behavior, Testing, andManufacturing Properties of Materials 562.1 Introduction 562.2 Tension 572.3 Compression 662.4 Torsion 672.5 Bending (Flexure) 682.6 Hardness 682.7 Fatigue 742.8 Creep 752.9 Impact 752.10 Failure and Fracture of Materials in Manufacturingand in Service 762.11 Residual Stresses 812.12 Work, Heat, and Temperature 82Summary 83 Key Terms 84 Bibliography 84Review Questions 84 Qualitative Problems 85Quantitative Problems 85 Synthesis, Design, and Projects 86 3 Physical Properties of Materials 883.1 Introduction 883.2 Density 893.3 Melting Point 923.4 Specific Heat 923.5 Thermal Conductivity 933.6 Thermal Expansion 933.7 Electrical, Magnetic, and Optical Properties 943.8 Corrosion Resistance 95Summary 97 Key Terms 97 Bibliography 98Review Questions 98 Qualitative Problems 98Quantitative Problems 98 Synthesis, Design, and Projects 99 4 Metal Alloys: Their Structure and Strengtheningby Heat Treatment 1004.1 Introduction 1004.2 Structure of Alloys 1014.3 Phase Diagrams 1034.4 The Iron-Carbon System 1074.5 The Iron-Iron-carbide Phase Diagram and the Developmentof Microstructures in Steels 1084.6 Cast Irons 1104.7 Heat Treatment of Ferrous Alloys 1114.8 Hardenability of Ferrous Alloys 1154.9 Heat Treatment of Nonferrous Alloys andStainless Steels 1174.10 Case Hardening 1194.11 Annealing 1214.12 Heat-treating Furnaces and Equipment 1234.13 Design Considerations for Heat Treating 125Summary 126 Key Terms 127 Bibliography 127Review Questions 127 Qualitative Problems 127Quantitative Problems 128 Synthesis, Design, and Projects 128 5 Ferrous Metals and Alloys: Production, GeneralProperties, and Applications 1295.1 Introduction 1295.2 Production of Iron and Steel 1305.3 Casting of Ingots 1335.4 Continuous Casting 1345.5 Carbon and Alloy Steels 1365.6 Stainless Steels 1435.7 Tool and Die Steels 145Summary 147 Key Terms 148 Bibliography 148Review Questions 148 Qualitative Problems 149Quantitative Problems 149 Synthesis, Design, and Projects 150 6 Nonferrous Metals and Alloys: Production,General Properties, and Applications 1516.1 Introduction 1516.2 Aluminum and Aluminum Alloys 1526.3 Magnesium and Magnesium Alloys 1576.4 Copper and Copper Alloys 1586.5 Nickel and Nickel Alloys 1606.6 Superalloys 1616.7 Titanium and Titanium Alloys 1626.8 Refractory Metals and Alloys 1636.9 Beryllium 1646.10 Zirconium 1646.11 Low-melting Alloys 1646.12 Precious Metals 1666.13 Shape-memory Alloys (Smart Materials) 1666.14 Amorphous Alloys (Metallic Glasses) 1676.15 Metal Foams 167Summary 168 Key Terms 168 Bibliography 169Review Questions 169 Qualitative Problems 169Quantitative Problems 170 Synthesis, Design, and Projects 170 7 Polymers: Structure, General Properties,and Applications 1717.1 Introduction 1717.2 The Structure of Polymers 1737.3 Thermoplastics 1807.4 Thermosetting Plastics 1847.5 Additives in Plastics 1847.6 General Properties and Applications of Thermoplastics 1857.7 General Properties and Applications of ThermosettingPlastics 1887.8 Biodegradable Plastics 1907.9 Elastomers (Rubbers) 191Summary 192 Key Terms 193 Bibliography 193Review Questions 194 Qualitative Problems 194Quantitative Problems 195 Synthesis, Design, and Projects 195 8 Ceramics, Graphite, Diamond, andNanomaterials: Structure, General Properties,and Applications 1968.1 Introduction 1968.2 The Structure of Ceramics 1978.3 General Properties and Applications of Ceramics 2018.4 Glasses 2058.5 Glass Ceramics 2078.6 Graphite 2088.7 Diamond 2108.8 Nanomaterials 210Summary 212 Key Terms 212 Bibliography 213Review Questions 213 Qualitative Problems 214Quantitative Problems 214 Synthesis, Design, and Projects 214 9 Composite Materials: Structure, GeneralProperties, and Applications 2169.1 Introduction 2169.2 The Structure of Reinforced Plastics 2179.3 Properties of Reinforced Plastics 2229.4 Applications of Reinforced Plastics 2259.5 Metal-matrix Composites 2279.6 Ceramic-matrix Composites 2299.7 Other Composites 230Summary 231 Key Terms 231 Bibliography 231Review Questions 232 Qualitative Problems 232Quantitative Problems 233 Synthesis, Design, and Projects 233 Part II: Metal-Casting Processesand Equipment 235 10 Fundamentals of Metal Casting 23710.1 Introduction 23710.2 Solidification of Metals 23810.3 Fluid Flow 24310.4 Fluidity of Molten Metal 24510.5 Heat Transfer 24710.6 Defects 249Summary 253 Key Terms 254 Bibliography 254Review Questions 254 Qualitative Problems 255Quantitative Problems 255 Synthesis, Design, and Projects 256 11 Metal-Casting Processes and Equipment 25811.1 Introduction 25811.2 Expendable-mold, Permanent-pattern Casting Processes 26211.3 Expendable-mold, Expendable-pattern Casting Processes 27011.4 Permanent-mold Casting Processes 27711.5 Casting Techniques for Single-crystal Components 28511.6 Rapid Solidification 28611.7 Inspection of Castings 28711.8 Melting Practice and Furnaces 28711.9 Foundries and Foundry Automation 289Summary 289 Key Terms 290 Bibliography 290Review Questions 291 Qualitative Problems 291Quantitative Problems 292 Synthesis, Design, and Projects 292 12 Metal Casting: Design, Materials,and Economics 29412.1 Introduction 29412.2 Design Considerations in Casting 29412.3 Casting Alloys 30212.4 Economics of Casting 307Summary 308 Key Terms 309 Bibliography 309Review Questions 309 Qualitative Problems 309Quantitative Problems 310 Synthesis, Design, and Projects 310 Part III: Forming and Shaping Processesand Equipment 313 13 Metal-Rolling Processes and Equipment 31613.1 Introduction 31613.2 The Flat-rolling Process 31813.3 Flat-rolling Practice 32213.4 Rolling Mills 32513.5 Various Rolling Processes and Mills 327Summary 332 Key Terms 333 Bibliography 333Review Questions 333 Qualitative Problems 333Quantitative Problems 334 Synthesis, Design, and Projects 334 14 Metal-Forging Processes and Equipment 33514.1 Introduction 33514.2 Open-die Forging 33714.3 Impression-die and Closed-die Forging 33914.4 Various Forging Operations 34314.5 Forgeability of Metals; Forging Defects 34814.6 Die Design, Die Materials, and Lubrication 34914.7 Die-manufacturing Methods and Die Failures 35114.8 Forging Machines 35314.9 Economics of Forging 355Summary 357 Key Terms 358 Bibliography 358Review Questions 358 Qualitative Problems 358Quantitative Problems 359 Synthesis, Design, and Projects 359 15 Metal Extrusion and Drawing Processesand Equipment 36015.1 Introduction 36015.2 The Extrusion Process 36215.3 Hot Extrusion 36415.4 Cold Extrusion 36815.5 Extrusion Defects 37115.6 Extrusion Equipment 37315.7 The Drawing Process 37315.8 Drawing Practice 37515.9 Drawing Defects and Residual Stresses 37715.10 Drawing Equipment 377Summary 378 Key Terms 378 Bibliography 379Review Questions 379 Qualitative Problems 379Quantitative Problems 380 Synthesis, Design, and Projects 380 16 Sheet-Metal Forming Processes andEquipment 38116.1 Introduction 38116.2 Shearing 38216.3 Sheet-metal Characteristics and Formability 39216.4 Formability Tests for Sheet Metals 39416.5 Bending Sheets, Plates, and Tubes 39716.6 Miscellaneous Bending and Related Operations 40116.7 Deep Drawing 40716.8 Rubber Forming and Hydroforming 41316.9 Spinning 41716.10 Superplastic Forming 42016.11 Specialized Forming Processes 42116.12 Manufacturing of Metal Honeycomb Structures 42616.13 Design Considerations in Sheet-metal Forming 42816.14 Equipment for Sheet-metal Forming 43016.15 Economics of Sheet-forming Operations 431Summary 432 Key Terms 433 Bibliography 433Review Questions 434 Qualitative Problems 434Quantitative Problems 435 Synthesis, Design, and Projects 435 17 Powder-Metal Processing and Equipment 43717.1 Introduction 43717.2 Production of Metal Powders 43817.3 Compaction of Metal Powders 44417.4 Sintering 45217.5 Secondary and Finishing Operations 45617.6 Design Considerations 45717.7 Process Capabilities 45917.8 Economics of Powder Metallurgy 460Summary 462 Key Terms 462 Bibliography 463Review Questions 463 Qualitative Problems 463Quantitative Problems 464 Synthesis, Design, and Projects 464 18 Ceramics, Glasses, and Superconductors:Processing and Equipment 46518.1 Introduction 46518.2 Shaping Ceramics 46618.3 Forming and Shaping of Glass 47218.4 Techniques for Strengthening and Annealing Glass 47618.5 Design Considerations for Ceramics and Glasses 47818.6 Processing of Superconductors 479Summary 480 Key Terms 481 Bibliography 481Review Questions 482 Qualitative Problems 482Quantitative Problems 482 Synthesis, Design, and Projects 483 19 Plastics and Composite Materials: Formingand Shaping 48419.1 Introduction 48419.2 Extrusion 48619.3 Injection Molding 49319.4 Blow Molding 49919.5 Rotational Molding 50119.6 Thermoforming 50219.7 Compression Molding 50319.8 Transfer Molding 50419.9 Casting 50519.10 Foam Molding 50619.11 Cold Forming and Solid-phase Forming 50719.12 Processing Elastomers 50719.13 Processing Polymer-matrix Composites 50819.14 Processing Metal-matrix and Ceramic-matrix Composites 51719.15 Design Considerations 51819.16 Economics of Processing Plastics and Composite Materials 520Summary 521 Key Terms 522 Bibliography 522Review Questions 523 Qualitative Problems 523Quantitative Problems 524 Synthesis, Design, and Projects 524 20 Rapid-Prototyping Processes andOperations 52520.1 Introduction 52520.2 Subtractive Processes 52820.3 Additive Processes 53020.4 Virtual Prototyping 54120.5 Direct Manufacturing and Rapid Tooling 542Summary 549 Key Terms 549 Bibliography 549Review Questions 550 Qualitative Problems 550Quantitative Problems 550 Synthesis, Design, and Projects 551 Part IV: Machining Processesand Machine Tools 553 21 Fundamentals of Machining 55621.1 Introduction 55621.2 Mechanics of Cutting 55821.3 Cutting Forces and Power 56821.4 Temperatures in Cutting 57121.5 Tool Life: Wear and Failure 57421.6 Surface Finish and Integrity 58121.7 Machinability 583Summary 587 Key Terms 588 Bibliography 588Review Questions 588 Qualitative Problems 589Quantitative Problems 589 Synthesis, Design, and Projects 590 22 Cutting-Tool Materials and Cutting Fluids 59122.1 Introduction 59122.2 High-speed Steels 59522.3 Cast-cobalt Alloys 59622.4 Carbides 59622.5 Coated Tools 60022.6 Alumina-based Ceramics 60422.7 Cubic Boron Nitride 60522.8 Silicon-nitride-based Ceramics 60522.9 Diamond 60522.10 Whisker-reinforced Materials and Nanomaterials 60622.11 Tool Costs and Reconditioning of Tools 60722.12 Cutting Fluids 607Summary 612 Key Terms 612 Bibliography 613Review Questions 613 Qualitative Problems 613Quantitative Problems 614 Synthesis, Design, and Projects 614 23 Machining Processes: Turning and HoleMaking 61523.1 Introduction 61523.2 The Turning Process 61823.3 Lathes and Lathe Operations 62623.4 Boring and Boring Machines 64123.5 Drilling, Drills, and Drilling Machines 64323.6 Reaming and Reamers 65223.7 Tapping and Taps 653Summary 655 Key Terms 656 Bibliography 656Review Questions 656 Qualitative Problems 657Quantitative Problems 657 Synthesis, Design, and Projects 658 24 Machining Processes: Milling, Broaching, Sawing,Filing, and Gear Manufacturing 65924.1 Introduction 65924.2 Milling and Milling Machines 66024.3 Planing and Shaping 67424.4 Broaching and Broaching Machines 67524.5 Sawing 67824.6 Filing 68124.7 Gear Manufacturing by Machining 681Summary 689 Key Terms 690 Bibliography 690Review Questions 690 Qualitative Problems 691Quantitative Problems 691 Synthesis, Design, and Projects 692 25 Machining Centers, Machine-Tool Structures,and Machining Economics 69325.1 Introduction 69325.2 Machining Centers 69425.3 Machine-tool Structures 70225.4 Vibration and Chatter in Machining Operations 70625.5 High-speed Machining 70925.6 Hard Machining 71125.7 Ultraprecision Machining 71125.8 Machining Economics 713Summary 717 Key Terms 717 Bibliography 717Review Questions 717 Qualitative Problems 718Quantitative Problems 718 Synthesis, Design, and Projects 718 26 Abrasive Machining and FinishingOperations 71926.1 Introduction 71926.2 Abrasives and Bonded Abrasives 72126.3 The Grinding Process 72726.4 Grinding Operations and Machines 73626.5 Design Considerations for Grinding 74426.6 Ultrasonic Machining 74426.7 Finishing Operations 74626.8 Deburring Operations 75026.9 Economics of Abrasive Machining and Finishing Operations 753Summary 754 Key Terms 755 Bibliography 755Review Questions 756 Qualitative Problems 756Quantitative Problems 757 Synthesis, Design, and Projects 757 27 Advanced Machining Processes 75927.1 Introduction 75927.2 Chemical Machining 76127.3 Electrochemical Machining 76527.4 Electrochemical Grinding 76827.5 Electrical-discharge Machining 76927.6 Laser-beam Machining 77427.7 Electron-beam Machining 77727.8 Water-jet Machining 77827.9 Abrasive-jet Machining 77927.10 Hybrid Machining Systems 78027.11 Economics of Advanced Machining Processes 781Summary 784 Key Terms 784 Bibliography 784Review Questions 785 Qualitative Problems 785Quantitative Problems 785 Synthesis, Design, and Projects 786 Part V: Micromanufacturing and Fabrication ofMicroelectronic Devices 787 28 Fabrication of Microelectronic Devices 79028.1 Introduction 79028.2 Clean Rooms 79328.3 Semiconductors and Silicon 79428.4 Crystal Growing and Wafer Preparation 79528.5 Film Deposition 79828.6 Oxidation 79928.7 Lithography 80028.8 Etching 80828.9 Diffusion and Ion Implantation 81628.10 Metallization and Testing 81828.11 Wire Bonding and Packaging 82028.12 Yield and Reliability 82528.13 Printed Circuit Boards 826Summary 827 Key Terms 828 Bibliography 828Review Questions 829 Qualitative Problems 829Quantitative Problems 830 Synthesis, Design, and Projects 830 29 Fabrication of Microelectromechanical Devicesand Systems and Nanoscale Manufacturing 83129.1 Introduction 83129.2 Micromachining of MEMS Devices 83329.3 The LIGA Microfabrication Process 84429.4 Solid Free-form Fabrication of Devices 85029.5 Nanoscale Manufacturing 855Summary 858 Key Terms 858 Bibliography 858Review Questions 859 Qualitative Problems 859Quantitative Problems 860 Synthesis, Design, and Projects 860 Part VI: Joining Processes andEquipment 861 30 Fusion-Welding Processes 86530.1 Introduction 86530.2 Oxyfuel-gas Welding 86630.3 Arc-welding Processes: Nonconsumable Electrode 86930.4 Arc-welding Processes: Consumable Electrode 87330.5 Electrodes for Arc Welding 87930.6 Electron-beam Welding 88030.7 Laser-beam Welding 88030.8 Cutting 88230.9 The Weld Joint, Quality, and Testing 88430.10 Joint Design and Process Selection 893Summary 897 Key Terms 897 Bibliography 898Review Questions 898 Qualitative Problems 898Quantitative Problems 899 Synthesis, Design, and Projects 899 31 Solid-State Welding Processes 90031.1 Introduction 90031.2 Cold Welding and Roll Bonding 90131.3 Ultrasonic Welding 90231.4 Friction Welding 90331.5 Resistance Welding 90531.6 Explosion Welding 91331.7 Diffusion Bonding 91431.8 Economics of Welding Operations 916Summary 918 Key Terms 919 Bibliography 919Review Questions 919 Qualitative Problems 919Quantitative Problems 920 Synthesis, Design, and Projects 920 32 Brazing, Soldering, Adhesive-Bonding,and Mechanical-Fastening Processes 92132.1 Introduction 92132.2 Brazing 92232.3 Soldering 92632.4 Adhesive Bonding 93132.5 Mechanical Fastening 93932.6 Joining Plastics, Ceramics, and Glasses 94232.7 Economics of Joining Operations 945Summary 946 Key Terms 947 Bibliography 947Review Questions 947 Qualitative Problems 948Quantitative Problems 948 Synthesis, Design, and Projects 948 Part VII: Surface Technology 949 33 Surface Roughness and Measurement; Friction,Wear, and Lubrication 95133.1 Introduction 95133.2 Surface Structure and Integrity 95233.3 Surface Texture and Roughness 95333.4 Friction 95733.5 Wear 96133.6 Lubrication 96433.7 Metalworking Fluids and Their Selection 966Summary 970 Key Terms 970 Bibliography 971Review Questions 971 Qualitative Problems 971Quantitative Problems 972 Synthesis, Design, and Projects 972 34 Surface Treatments, Coatings, and Cleaning 97334.1 Introduction 97334.2 Mechanical Surface Treatments 97434.3 Mechanical Plating and Cladding 97634.4 Case Hardening and Hard Facing 97634.5 Thermal Spraying 97734.6 Vapor Deposition 97934.7 Ion Implantation and Diffusion Coating 98234.8 Laser Treatments 98234.9 Electroplating, Electroless Plating, and Electroforming 98334.10 Conversion Coatings 98634.11 Hot Dipping 98734.12 Porcelain Enameling; Ceramic and Organic Coatings 98834.13 Diamond Coating and Diamondlike Carbon 98934.14 Surface Texturing 99034.15 Painting 99034.16 Cleaning of Surfaces 991Summary 993 Key Terms 993 Bibliography 993Review Questions 994 Qualitative Problems 994Quantitative Problems 994 Synthesis, Design, and Projects 995 Part VIII: Engineering Metrology,Instrumentation, and QualityAssurance 997 35 Engineering Metrology andInstrumentation 99835.1 Introduction 99835.2 Measurement Standards 99935.3 Geometric Features of Parts; Analog and DigitalMeasurements 100035.4 Traditional Measuring Methods and Instruments 100135.5 Modern Measuring Instruments and Machines 100835.6 Automated Measurement and Inspection 101135.7 General Characteristics and Selection of MeasuringInstruments 101235.8 Geometric Dimensioning and Tolerancing 1012Summary 1017 Key Terms 1017 Bibliography 1017Review Questions 1018 Qualitative Problems 1018Quantitative Problems 1018 Synthesis, Design, and Projects 1019 36 Quality Assurance, Testing, and Inspection 102036.1 Introduction 102036.2 Product Quality 102136.3 Quality Assurance 102236.4 Total Quality Management 102336.5 Taguchi Methods 102536.6 The ISO and QS Standards 102936.7 Statistical Methods of Quality Control 103036.8 Statistical Process Control 103336.9 Reliability of Products and Processes 103936.10 Nondestructive Testing 104036.11 Destructive Testing 104436.12 Automated Inspection 1044Summary 1045 Key Terms 1045 Bibliography 1046Review Questions 1046 Qualitative Problems 1047Quantitative Problems 1047 Synthesis, Design, and Projects 1047 Part IX: Manufacturing in a CompetitiveEnvironment 1049 37Automation of Manufacturing Processes 105137.1 Introduction 105137.2 Automation 105337.3 Numerical Control 106037.4 Adaptive Control 106637.5 Material Handling and Movement 106837.6 Industrial Robots 107137.7 Sensor Technology 107737.8 Flexible Fixturing 108137.9 Assembly Systems 108337.10 Design Considerations for Fixturing, Assembly, Disassembly,and Servicing 108637.11 Economic Considerations 1089Summary 1089 Key Terms 1090 Bibliography 1090Review Questions 1091 Qualitative Problems 1091Quantitative Problems 1092 Synthesis, Design, and Projects 1092 38 Computer-Aided Manufacturing 109338.1 Introduction 109338.2 Manufacturing Systems 109438.3 Computer-integrated Manufacturing 109438.4 Computer-aided Design and Engineering 109738.5 Computer-aided Manufacturing 110438.6 Computer-aided Process Planning 110438.7 Computer Simulation of Manufacturing Processesand Systems 110738.8 Group Technology 1108Summary 1115 Key Terms 1115 Bibliography 1115Review Questions 1116 Qualitative Problems 1116Synthesis, Design, and Projects 1116 39 Computer-Integrated ManufacturingSystems 111739.1 Introduction 111739.2 Cellular Manufacturing 111839.3 Flexible Manufacturing Systems 112039.4 Holonic Manufacturing 112239.5 Just-in-time Production 112439.6 Lean Manufacturing 112539.7 Communications Networks in Manufacturing 112739.8 Artificial Intelligence 112939.9 Economic Considerations 1132Summary 1132 Key Terms 1133 Bibliography 1133Review Questions 1134 Qualitative Problems 1134Synthesis, Design, and Projects 1134 40 Product Design and Process Selectionin a Competitive Environment 113540.1 Introduction 113540.2 Product Design 113640.3 Product Quality and Life Expectancy 113940.4 Life-cycle Assessment and Sustainable Manufacturing 114040.5 Material Selection for Products 114240.6 Material Substitution 114640.7 Manufacturing Process Capabilities 114840.8 Process Selection 115240.9 Manufacturing Costs and Cost Reduction 1156Summary 1161 Key Terms 1161 Bibliography 1162Review Questions 1162 Qualitative Problems 1162Synthesis, Design, and Projects 1163Index 1165 Case Studies11.1: Lost-foam Casting of Engine Blocks 27211.2: Investment Casting of Total Knee Replacements 27514.1: Manufacture of a Stepped Pin by Heading and PiercingOperations 34514.2: Suspension Components for the Lotus Elise Automobile 35616.1: Manufacturing of Food and Beverage Cans 41216.2: Tube Hydroforming of an Automotive Radiator Closure 41516.3: Cymbal Manufacture 42417.1: Powder Metallurgy Parts in a Snowblower 46118.1: Production of High-temperature Superconducting Tapes 48019.1: Manufacture of Head Protector (TM) Tennis Racquets 51520.1: Invisalign (R) Orthodontic Aligners 54323.1: Bone Screw Retainer 65424.1: Ping Golf Putter 68827.1: Electrochemical Machining of a Biomedical Implant 76727.2: Manufacture of Small Satellites 78129.1: Digital Micromirror Device 83729.2: Accelerometer for Automotive Air Bags 85131.1: Friction Welding of Pistons 91732.1: Light Curing Acrylic Adhesives for Medical Products 93736.1: Manufacture of Television Sets by Sony Corporation 102836.2: Dimensional Control of Plastic Parts in Saturn Automobiles 103837.1: Robotic Deburring of a Blow-molded Toboggan 107638.1: CAD Model Development for Automotive Components 110140.1: Automobile Tires: From Cradle-to-grave to Cradle-to-cradle 1141
Manufacturing Engineering & Technology, 6/e, presents a mostly qualitative description of the science, technology, and practice of manufacturing. This includes detailed descriptions of manufacturing processes and the manufacturing enterprise that will help introduce students to important concepts.
With a total of 120 examples and case studies, up-to-date and comprehensive coverage of all topics, and superior two-color graphics, this text provides a solid background for manufacturing students and serves as a valuable reference text for professionals.
The Sixth Edition has been completely updated, and addresses issues essential to modern manufacturing, ranging from traditional topics such as casting, forming, machining, and joining, to advanced topics such as the fabrication of microelectronic devices and microelectromechanical systems (MEMS), and nanomaterials and nanomanufacturing.
With each purchase of a new copy of the Sixth Edition, students receive access to Video Solutions and myeBook, Pearson's new visual tools for teaching and reinforcing key concepts and techniques.
9780136081685 0136081681 9780136081692 (hbk.) 013608169X (hbk.) 9810681445 9789810681449
Production engineering.
Manufacturing processes.
670.42 / K.S.M