DeGarmo's materials and processes in manufacturing
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DeGarmo's materials and processes in manufacturing
John Wiley & Sons Inc., c2013
11th ed., international student version
- pbk.
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Contains web registration card
Includes bibliographical references and index
Description and Table of Contents
Description
The new edition of DeGarmo's
Materials and Processes in Manufacturing focuses on updates and more coverage of non-metallic materials, sustainability, lean manufacturing, rapid prototyping and revised end of chapter and case study content. It emphasizes application and design, present mathematical models and analytic equations sparingly and uses case studies to highlight real world examples of manufacturing.
Other revisions and updates include the addition of frontend Learning Objectives; elimination of weak problems and addition of new problems; more relevant and current case studies as well as additional new ones where appropriate; new chapter on Rapid Prototyping; expanded coverage of non-metallic materials such as composites, polymers, etc. ; a discussion about sustainability and green, and engineering and how it relates to manufacturing; coverage of lean manufacturing and production; and updated references and chapter summaries.
Table of Contents
Chapter 1 Introduction to DeGarmo's Materials and Processes in Manufacturing
1.1 Materials, Manufacturing, and the Standardof Living
1.2 Manufacturing and Production Systems
Case Study Famous Manufacturing Engineers
Chapter 2 Manufacturing Systems Design
2.1 Introduction
2.2 Manufacturing Systems
2.3 Control of the Manufacturing System
2.4 Classification of Manufacturing Systems
2.5 Summary of Factory Designs
Case Study Jury Duty for an Engineer
Chapter 3 Properties of Materials
3.1 Introduction
3.2 Static Properties
3.3 Dynamic Properties
3.4 Temperature Effects (Both High and Low)
3.5 Machinability, Formability, and Weldability
3.6 Fracture Toughness and the Fracture Mechanics Approach
3.7 Physical Properties
3.8 Testing Standards and Testing Concerns
Case Study Separation of Mixed Materials
Chapter 4 Nature of Metals and Alloys
4.1 Structure Property Processing Performance Relationships
4.2 The Structure of Atoms
4.3 Atomic Bonding
4.4 Secondary Bonds
4.5 Atom Arrangements in Materials
4.6 Crystal Structures of Metals
4.7 Development of a Grain Structure
4.8 Elastic Deformation
4.9 Plastic Deformation
4.10 Dislocation Theory of Slippage
4.11 Strain Hardening or Work Hardening
4.12 Plastic Deformation in Polycrystalline Metals
4.13 Grain Shape and Anisotropic Properties
4.14 Fracture of Metals
4.15 Cold Working, Recrystallization, and Hot Working
4.16 Grain Growth
4.17 Alloys and Alloy Types
4.18 Atomic Structure and Electrical Properties
Chapter 5 Equilibrium Phase Diagrams and the Iron Carbon System
5.1 Introduction
5.2 Phases
5.3 Equilibrium Phase Diagrams
5.4 Iron Carbon Equilibrium Diagram
5.5 Steels and the Simplified Iron Carbon Diagram
5.6 Cast Irons
Case Study Fish Hooks
Chapter 6 Heat Treatment
6.1 Introduction
6.2 Processing Heat Treatments
6.3 Heat Treatments Used to Increase Strength
6.4 Strengthening Heat Treatments for Nonferrous Metals
6.5 Strengthening Heat Treatments for Steel
6.6 Surface Hardening of Steel
6.7 Furnaces
6.8 Heat Treatment and Energy
Case Study A Carpenter s Claw Hammer
Chapter 7 Ferrous Metals and Alloys
7.1 Introduction to History-Dependent Materials
7.2 Ferrous Metals
7.3 Iron
7.4 Steel
7.5 Stainless Steels
7.6 Tool Steels
7.7 Cast Irons
7.8 Cast Steels
7.9 The Role of Processing on Cast Properties
Case Study The Paper Clip
Chapter 8 Nonferrous Metals and Alloys
8.1 Introduction
8.2 Copper and Copper Alloys
8.3 Aluminum and Aluminum Alloys
8.4 Magnesium and Magnesium Alloys
8.5 Zinc and Zinc Alloys
8.6 Titanium and Titanium Alloys
8.7 Nickel-Based Alloys
8.8 Superalloys, Refractory Metals, and Other Materials Designed for High-Temperature Service
8.9 Lead and Tin, and Their Alloys
8.10 Some Lesser-Known Metals and Alloys
8.11 Metallic Glasses
8.12 Graphite
Case Study Hip Replacement Prosthetics
Chapter 9 Nonmetallic Materials: Plastics, Elastomers, Ceramics, and Composites
9.1 Introduction
9.2 Plastics
9.3 Elastomers
9.4 Ceramics
9.5 Composite Materials
Case Study Lightweight Armor
Chapter 10 Material Selection
10.1 Introduction
10.2 Material Selection and Manufacturing Processes
10.3 The Design Process
10.4 Approaches to Material Selection
10.5 Additional Factors to Consider
10.6 Consideration of the Manufacturing Process
10.7 Ultimate Objective
10.8 Materials Substitution
10.9 Effect of Product Liability on Materials Selection
10.10 Aids to Material Selection
Case Study Material Selection
Chapter 11 Fundamentals of Casting
11.1 Introduction to Materials Processing
11.2 Introduction to Casting
11.3 Casting Terminology
11.4 The Solidification Process
11.5 Patterns
11.6 Design Considerations in Castings
11.7 The Casting Industry
Case Study The Cast Oil-Field Fitting
Chapter 12 Expendable-Mold Casting Processes
12.1 Introduction
12.2 Sand Casting
12.3 Cores and Core Making
12.4 Other Expendable-Mold Processes with Multiple-Use Patterns
12.5 Expendable-Mold Processes Using Single-Use Patterns
12.6 Shakeout, Cleaning, and Finishing
12.7 Summary
Case Study Movable and Fixed Jaw Pieces for a Heavy-Duty Bench Vise
Chapter 13 Multiple-Use-Mold Casting Processes
13.1 Introduction
13.2 Permanent-Mold Casting
13.3 Die Casting
13.4 Squeeze Casting and Semisolid Casting
13.5 Centrifugal Casting
13.6 Continuous Casting
13.7 Melting
13.8 Pouring Practice
13.9 Cleaning, Finishing, and Heat Treating of Castings
13.10 Automation in Foundry Operations
13.11 Process Selection
Case Study Baseplate for a Household Steam Iron
Chapter 14 Fabrication of Plastics, Ceramics, and Composites
14.1 Introduction
14.2 Fabrication of Plastics
14.3 Processing of Rubber and Elastomers
14.4 Processing of Ceramics
14.5 Fabrication of Composite Materials
Case Study Automotive and Light Truck Fuel Tanks
Chapter 15 Fundamentals of Metal Forming
15.1 Introduction
15.2 Forming Processes: Independent Variables
15.3 Dependent Variables
15.4 Independent Dependent Relationships
15.5 Process Modeling
15.6 General Parameters
15.7 Friction and Lubrication Under Metalworking Conditions
15.8 Temperature Concerns
15.9 Formability
Case Study Interior Tub of a Top-Loading Washing Machine
Chapter 16 Bulk-Forming Processes
16.1 Introduction
16.2 Classification of Deformation Processes
16.3 Bulk Deformation Processes
16.4 Rolling
16.5 Forging
16.6 Extrusion
16.7 Wire, Rod, and Tube Drawing
16.8 Cold Forming, Cold Forging, and Impact Extrusion
16.9 Piercing
16.10 Other Squeezing Processes
16.11 Surface Improvement by Deformation Processing
Case Study Handle and Body of a Large Ratchet Wrench
Chapter 17 Sheet-Forming Processes
17.1 Introduction
17.2 Shearing Operations
17.3 Bending
17.4 Drawing and Stretching Processes
17.5 Alternative Methods of Producing Sheet-Type Products
17.6 Pipe Manufacture
17.7 Presses
Case Study Automotive Body Panels
Chapter 18 Powder Metallurgy
18.1 Introduction
18.2 The Basic Process
18.3 Powder Manufacture
18.4 Microcrystalline and Amorphous Material Produced by Rapid Cooling
18.5 Powder Testing and Evaluation
18.6 Powder Mixing and Blending
18.7 Compacting
18.8 Sintering
18.9 Recent Advances in Sintering
18.10 Hot-Isostatic Pressing
18.11 Other Techniques to Produce High-Density Powder Metallurgy Products
18.12 Metal Injection Molding or Powder Injection Molding
18.13 Secondary Operations
18.14 Properties of Powder Metallurgy Products
18.15 Design of Powder Metallurgy Parts
18.16 Powder Metallurgy Products
18.17 Advantages and Disadvantages of Powder Metallurgy
18.18 Process Summary
Case Study Steering Gear for a Riding Lawn Mower/Garden Tractor
Chapter 19 Additive Processes: Rapid Prototyping and Direct- Digital Manufacturing
19.1 Introduction
19.2 Rapid Prototyping and Direct-Digital Manufacturing
19.3 Layerwise Manufacturing
19.4 Liquid-Based Processes
19.5 Powder-Based Processes
19.6 Deposition-Based Processes
19.7 Uses and Applications
19.8 Pros, Cons, and Current and Future Trends
19.9 Economic Considerations
Chapter 20 Fundamentals of Machining/Orthogonal Machining
20.1 Introduction
20.2 Fundamentals
20.3 Forces and Power in Machining
20.4 Orthogonal Machining (Two Forces)
20.5 Chip Thickness Ratio, rc
20.6 Mechanics of Machining (Statics)
20.7 Shear Strain, g, and Shear Front Angle, w
20.8 Mechanics of Machining (Dynamics)
20.9 Summary
Case Study Orthogonal Plate Machining Experiment at Auburn University
Chapter 21 Cutting Tools for Machining
21.1 Introduction
21.2 Cutting Tool Materials
21.3 Tool Geometry
21.4 Tool-Coating Processes
21.5 Tool Failure and Tool Life
21.6 Flank Wear
21.7 Cutting Fluids
21.8 Economics of Machining
Case Study Comparing Tool Materials Based on Tool Life
Chapter 22 Turning and Boring Processes
22.1 Introduction
22.2 Fundamentals of Turning, Boring, and Facing Turning
22.3 Lathe Design and Terminology
22.4 Cutting Tools for Lathes
22.5 Workholding in Lathes
Case Study Estimating the Machining Time for Turning
Chapter 23 Drilling and Related Hole-Making Processes
23.1 Introduction
23.2 Fundamentals of the Drilling Process
23.3 Types of Drills
23.4 Tool Holders for Drills
23.5 Workholding for Drilling
23.6 Machine Tools for Drilling
23.7 Cutting Fluids for Drilling
23.8 Counterboring, Countersinking, and Spot Facing
23.9 Reaming
Case Study Bolt-down Leg on a Casting
Chapter 24 Milling
24.1 Introduction
24.2 Fundamentals of Milling Processes
24.3 Milling Tools and Cutters
24.4 Machines for Milling
Case Study HSS versus Tungsten Carbide Milling
Chapter 25 NC/CNC Processes and Adaptive Control: A(4) and A(5) Levels of Automation
25.1 Introduction
25.2 Basic Principles of Numerical Control
25.3 Machining Center Features and Trends
25.4 Ultra-High-Speed Machining Centers
25.5 Summary
Chapter 26 Abrasive Machining Processes
26.1 Introduction
26.2 Abrasives
26.3 Grinding Wheel Structure and Grade
26.4 Grinding Wheel Identification
26.5 Grinding Machines
26.6 Honing
26.7 Superfinishing
26.8 Free Abrasives
26.9 Design Considerations In Grinding
Case Study Process Planning for the MfE
Chapter 27 Workholding Devices for Machine Tools
27.1 Introduction
27.2 Conventional Fixture Design
27.3 Tool Design Steps
27.4 Clamping Considerations
27.5 Chip Disposal
27.6 Unloading and Loading Time
27.7 Example of Jig Design
27.8 Types of Jigs
27.9 Conventional Fixtures
27.10 Modular Fixturing
27.11 Setup and Changeover
27.12 Clamps
27.13 Other Workholding Devices
27.14 Economic Justification of Jigs and Fixtures
Case Study Fixture versus No Fixture in Milling
Chapter 28 Nontraditional Manufacturing Processes
28.1 Introduction
28.2 Chemical Machining Processes
28.3 Electrochemical Machining Processes
28.4 Electrical Discharge Machining
Case Study Vented Cap Screws
Chapter 29 Fundamentals of Joining
29.1 Introduction to Consolidation Processes
29.2 Classification of Welding and Thermal Cutting Processes
29.3 Some Common Concerns
29.4 Types of Fusion Welds and Types of Joints
29.5 Design Considerations
29.6 Heat Effects
29.7 Weldability or Joinability
29.8 Summary
Chapter 30 Gas Flame and Arc Processes
30.1 Oxyfuel-Gas Welding
30.2 Oxygen Torch Cutting
30.3 Flame Straightening
30.4 Arc Welding
30.5 Consumable-Electrode Arc Welding
30.6 Nonconsumable-Electrode Arc Welding
30.7 Welding Equipment
30.8 Arc Cutting
30.9 Metallurgical and Heat Effects in Thermal Cutting
Case Study Bicycle Frame Construction and Repair
Chapter 31 Resistance- and Solid-State Welding Processes
31.1 Introduction
31.2 Theory of Resistance Welding
31.3 Resistance-Welding Processes
31.4 Advantages and Limitations of Resistance Welding
31.5 Solid-State Welding Processes
Case Study Manufacture of an Automobile Muffler
Chapter 32 Other Welding Processes, Brazing, and Soldering
32.1 Introduction
32.2 Other Welding and Cutting Processes
32.3 Surface Modification by Welding-Related Processes
32.4 Brazing
32.5 Soldering
Case Study Impeller of a Pharmaceutical Company Industrial Shredder/Disposal
Chapter 33 Adhesive Bonding, Mechanical Fastening, and Joining of Nonmetals
33.1 Adhesive Bonding
33.2 Mechanical Fastening
33.3 Joining of Plastics
33.4 Joining of Ceramics and Glass
33.5 Joining of Composites
Case Study Golf Club Heads with Insert
Chapter 34 Surface Engineering
34.1 Introduction
34.2 Abrasive Cleaning and Finishing
34.3 Chemical Cleaning
34.4 Coatings
34.5 Vaporized Metal Coatings
34.6 Clad Materials
34.7 Textured Surfaces
34.8 Coil-Coated Sheets
34.9 Edge Finishing and Burrs
Case Study Dana Lynn s Fatigue Lesson
Chapter 35 Microelectric Manufacturing and Assembly
35.1 Introduction
35.2 How Electronic Products Are Made
35.3 Semiconductors
35.4 How Integrated Circuits Are Made
35.5 How the Silicon Wafer Is Made
35.6 Fabricating Integrated Circuits on Silicon Wafers
35.7 Thin-Film Deposition
35.8 Integrated Circuit Packaging
35.9 Printed Circuit Boards
35.10 Electronic Assembly
Chapter 36 Micro/Meso/Nano Fabrication Processes
36.1 Introduction
36.2 Additive Processes
36.3 Metrology at the Micro/Meso/Nano Level
Chapter 37 Measurement and Inspection (online only)
37.1 Introduction
37.2 Standards of Measurement
37.3 Allowance and Tolerance
37.4 Inspection Methods for Measurement
37.5 Measuring Instruments
37.6 Vision Systems for Measurement
37.7 Coordinate Measuring Machines
37.8 Angle-Measuring Instruments
37.9 Gages for Attributes Measuring
Case Study Measuring An Angle
Chapter 38 Nondestructive Inspection and Testing (online only)
38.1 Destructive versus Nondestructive Testing
38.2 Other Methods of Nondestructive Testing and Inspection
Advanced Topic 1 - Lean Engineering (online only)
A1.1 Introduction
A1.2 The Lean Engineer
A1.3 The Lean Production System
A1.4 Linked-Cell Manufacturing System Design Rules
A1.5 Manufacturing System Designs
A1.6 Preliminary Steps to Lean Production
A1.7 Methodology for Implementation of Lean Production
A1.8 Design Rule MT < CT
A1.9 Decouplers
A1.10 Integrating Production Control
A1.11 Integrating Inventory Control
A1.12 Lean Manufacturing Cell Design
A1.13 Machine Tool Design for Lean Manufacturing Cells
A1.14 L-CMS Strategy
Case Study Cycle Time for a Manufacturing Cell
Advanced Topic 2 - Quality Engineering (online only)
A2.1 Introduction
A2.2 Determining Process Capability
A2.3 Introduction to Statistical Quality Control
A2.4 Sampling Errors
A2.5 Gage Capability
A2.6 Just in Time/Total Quality Control
A2.7 Six Sigma
A2.8 Summary
Case Study Boring QC Chart Blunders
Advanced Topic 3 - The Enterprise (Production Systems) (online only)
A3.1 Introduction
A3.2 Axiomatic Design of Systems
A3.3 Enterprise System Design Principles
A3.4 Functional Areas in the Production System
A3.5 Human Resources (Personnel) Department
Index
Selected References for Additional Study
by "Nielsen BookData"