كتاب Fundamentals of Modern Manufacturing Materials, Processes, and Systems 4th Edition

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Fundamentals of Modern Manufacturing Materials, Processes, and Systems 4th Edition

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CONTENTS
1 INTRODUCTION AND OVERVIEW
OF MANUFACTURING 1
1.1 What Is Manufacturing? 2
1.2 Materials in Manufacturing 7
1.3 Manufacturing Processes 10
1.4 Production Systems 16
1.5 Trends in Manufacturing 20
1.6 Organization of the Book 23
Part I Material Properties and Product
Attributes 25
2 THE NATURE OF MATERIALS 25
2.1 Atomic Structure and the Elements 26
2.2 Bonding between Atoms and Molecules 28
2.3 Crystalline Structures 30
2.4 Noncrystalline (Amorphous)
Structures 35
2.5 Engineering Materials 37
3 MECHANICAL PROPERTIES OF
MATERIALS 40
3.1 Stress–Strain Relationships 40
3.2 Hardness 52
3.3 Effect of Temperature on Properties 56
3.4 Fluid Properties 58
3.5 Viscoelastic Behavior of Polymers 60
4 PHYSICAL PROPERTIES OF
MATERIALS 67
4.1 Volumetric and Melting Properties 67
4.2 Thermal Properties 70
4.3 Mass Diffusion 72
4.4 Electrical Properties 73
4.5 Electrochemical Processes 75
5 DIMENSIONS, SURFACES, AND
THEIR MEASUREMENT 78
5.1 Dimensions, Tolerances, and
Related Attributes 78
5.2 Conventional Measuring Instruments
and Gages 79
5.3 Surfaces 87
5.4 Measurement of Surfaces 92
5.5 Effect of Manufacturing Processes 94
Part II Engineering Materials 98
6 METALS 98
6.1 Alloys and Phase Diagrams 99
6.2 Ferrous Metals 103
6.3 Nonferrous Metals 120
6.4 Superalloys 131
6.5 Guide to the Processing of Metals 132
7 CERAMICS 136
7.1 Structure and Properties of Ceramics 137
7.2 Traditional Ceramics 139
7.3 New Ceramics 142
7.4 Glass 144
7.5 Some Important Elements Related to
Ceramics 148
7.6 Guide to Processing Ceramics 150
8 POLYMERS 153
8.1 Fundamentals of Polymer Science
and Technology 155
8.2 Thermoplastic Polymers 165
8.3 Thermosetting Polymers 171
8.4 Elastomers 175
8.5 Polymer Recycling and Biodegradability 182
8.6 Guide to the Processing of Polymers 184
9 COMPOSITE MATERIALS 187
9.1 Technology and Classification of
Composite Materials 188
9.2 Metal Matrix Composites 196
9.3 Ceramic Matrix Composites 198
9.4 Polymer Matrix Composites 199
9.5 Guide to Processing Composite Materials 201
Part III Solidification Processes 205
10 FUNDAMENTALS OF METAL CASTING 205
10.1 Overview of Casting Technology 207
10.2 Heating and Pouring 210
10.3 Solidification and Cooling 213
11 METAL CASTING PROCESSES 225
11.1 Sand Casting 225
11.2 Other Expendable-Mold Casting Processes 230
ix
11.3 Permanent-Mold Casting Processes 237
11.4 Foundry Practice 245
11.5 Casting Quality 249
11.6 Metals for Casting 251
11.7 Product Design Considerations 253
12 GLASSWORKING 258
12.1 Raw Materials Preparation and Melting 258
12.2 Shaping Processes in Glassworking 259
12.3 Heat Treatment and Finishing 264
12.4 Product Design Considerations 266
13 SHAPING PROCESSES FOR PLASTICS 268
13.1 Properties of Polymer Melts 269
13.2 Extrusion 271
13.3 Production of Sheet and Film 281
13.4 Fiber and Filament Production (Spinning) 284
13.5 Coating Processes 285
13.6 Injection Molding 286
13.7 Compression and Transfer Molding 295
13.8 Blow Molding and Rotational Molding 298
13.9 Thermoforming 302
13.10 Casting 306
13.11 Polymer Foam Processing and Forming 307
13.12 Product Design Considerations 308
14 RUBBER-PROCESSING TECHNOLOGY 315
14.1 Rubber Processing and Shaping 315
14.2 Manufacture of Tires and Other Rubber
Products 320
14.3 Product Design Considerations 324
15 SHAPING PROCESSES FOR POLYMER
MATRIX COMPOSITES 327
15.1 Starting Materials for PMCs 329
15.2 Open Mold Processes 331
15.3 Closed Mold Processes 335
15.4 Filament Winding 337
15.5 Pultrusion Processes 339
15.6 Other PMC Shaping Processes 341
Part IV Particulate Processing of Metals and
Ceramics 344
16 POWDER METALLURGY 344
16.1 Characterization of Engineering Powders 347
16.2 Production of Metallic Powders 350
16.3 Conventional Pressing and Sintering 352
16.4 Alternative Pressing and Sintering
Techniques 358
16.5 Materials and Products for Powder
Metallurgy 361
16.6 Design Considerations in Powder
Metallurgy 362
17 PROCESSING OF CERAMICS
AND CERMETS 368
17.1 Processing of Traditional Ceramics 368
17.2 Processing of New Ceramics 376
17.3 Processing of Cermets 378
17.4 Product Design Considerations 380
Part V Metal Forming and Sheet Metalworking 383
18 FUNDAMENTALS OF METAL
FORMING 383
18.1 Overview of Metal Forming 383
18.2 Material Behavior in Metal Forming 386
18.3 Temperature in Metal Forming 387
18.4 Strain Rate Sensitivity 389
18.5 Friction and Lubrication in Metal Forming 391
19 BULK DEFORMATION PROCESSES
IN METAL WORKING 395
19.1 Rolling 396
19.2 Other Deformation Processes Related to
Rolling 403
19.3 Forging 405
19.4 Other Deformation Processes Related
to Forging 416
19.5 Extrusion 420
19.6 Wire and Bar Drawing 430
20 SHEET METALWORKING 443
20.1 Cutting Operations 444
20.2 Bending Operations 450
20.3 Drawing 454
20.4 Other Sheet-Metal-Forming Operations 461
20.5 Dies and Presses for Sheet-Metal
Processes 464
20.6 Sheet-Metal Operations Not Performed
on Presses 471
20.7 Bending of Tube Stock 476
Part VI Material Removal Processes 483
21 THEORY OF METAL MACHINING 483
21.1 Overview of Machining Technology 485
21.2 Theory of Chip Formation in Metal
Machining 488
21.3 Force Relationships and the Merchant
Equation 492
21.4 Power and Energy Relationships
in Machining 497
21.5 Cutting Temperature 500
x Contents
22 MACHINING OPERATIONS AND
MACHINE TOOLS 507
22.1 Machining and Part Geometry 507
22.2 Turning and Related Operations 510
22.3 Drilling and Related Operations 519
22.4 Milling 523
22.5 Machining Centers and Turning Centers 530
22.6 Other Machining Operations 533
22.7 Machining Operations for
Special Geometries 537
22.8 High-Speed Machining 545
23 CUTTING-TOOL TECHNOLOGY 552
23.1 Tool Life 552
23.2 Tool Materials 559
23.3 Tool Geometry 567
23.4 Cutting Fluids 577
24 ECONOMIC AND PRODUCT DESIGN
CONSIDERATIONS IN MACHINING 585
24.1 Machinability 585
24.2 Tolerances and Surface Finish 587
24.3 Selection of Cutting Conditions 591
24.4 Product Design Considerations
in Machining 597
25 GRINDING AND OTHER ABRASIVE
PROCESSES 604
25.1 Grinding 604
25.2 Related Abrasive Processes 621
26 NONTRADITIONAL MACHINING AND
THERMAL CUTTING PROCESSES 628
26.1 Mechanical Energy Processes 629
26.2 Electrochemical Machining Processes 632
26.3 Thermal Energy Processes 636
26.4 Chemical Machining 644
26.5 Application Considerations 650
Part VII Property Enhancing and Surface Processing
Operations 656
27 HEAT TREATMENT OF METALS 656
27.1 Annealing 657
27.2 Martensite Formation in Steel 657
27.3 Precipitation Hardening 661
27.4 Surface Hardening 663
27.5 Heat Treatment Methods and Facilities 664
28 SURFACE PROCESSING OPERATIONS 668
28.1 Industrial Cleaning Processes 668
28.2 Diffusion and Ion Implantation 673
28.3 Plating and Related Processes 674
28.4 Conversion Coating 678
28.5 Vapor Deposition Processes 680
28.6 Organic Coatings 685
28.7 Porcelain Enameling and Other Ceramic
Coatings 688
28.8 Thermal and Mechanical Coating
Processes 689
Part VIII Joining and Assembly Processes 693
29 FUNDAMENTALS OF WELDING 693
29.1 Overview of Welding Technology 695
29.2 The Weld Joint 697
29.3 Physics of Welding 700
29.4 Features of a Fusion-Welded Joint 704
30 WELDING PROCESSES 709
30.1 Arc Welding 709
30.2 Resistance Welding 719
30.3 Oxyfuel Gas Welding 726
30.4 Other Fusion-Welding Processes 729
30.5 Solid-State Welding 732
30.6 Weld Quality 738
30.7 Weldability 742
30.8 Design Considerations in Welding 742
31 BRAZING, SOLDERING, AND ADHESIVE
BONDING 748
31.1 Brazing 748
31.2 Soldering 754
31.3 Adhesive Bonding 758
32 MECHANICAL ASSEMBLY 766
32.1 Threaded Fasteners 767
32.2 Rivets and Eyelets 773
32.3 Assembly Methods Based on
Interference Fits 774
32.4 Other Mechanical Fastening
Methods 777
32.5 Molding Inserts and Integral
Fasteners 778
32.6 Design for Assembly 779
Part IX Special Processing and Assembly
Technologies 786
33 RAPID PROTOTYPING 786
33.1 Fundamentals of Rapid Prototyping 787
33.2 Rapid Prototyping Technologies 788
33.3 Application Issues in Rapid Prototyping 795
Contents xi
34 PROCESSING OF INTEGRATED
CIRCUITS 800
34.1 Overview of IC Processing 800
34.2 Silicon Processing 805
34.3 Lithography 809
34.4 Layer Processes Used in IC
Fabrication 812
34.5 Integrating the Fabrication Steps 818
34.6 IC Packaging 820
34.7 Yields in IC Processing 824
35 ELECTRONICS ASSEMBLY AND
PACKAGING 830
35.1 Electronics Packaging 830
35.2 Printed Circuit Boards 832
35.3 Printed Circuit Board Assembly 840
35.4 Surface-Mount Technology 843
35.5 Electrical Connector Technology 847
36 MICROFABRICATION
TECHNOLOGIES 853
36.1 Microsystem Products 853
36.2 Microfabrication Processes 859
37 NANOFABRICATION
TECHNOLOGIES 869
37.1 Nanotechnology Products 870
37.2 Introduction to Nanoscience 873
37.3 Nanofabrication Processes 877
Part X Manufacturing Systems 886
38 AUTOMATION TECHNOLOGIES FOR
MANUFACTURING SYSTEMS 886
38.1 Automation Fundamentals 887
38.2 Hardware Components for
Automation 890
38.3 Computer Numerical Control 894
38.4 Industrial Robotics 907
39 INTEGRATED MANUFACTURING
SYSTEMS 918
39.1 Material Handling 918
39.2 Fundamentals of Production Lines 920
39.3 Manual Assembly Lines 923
39.4 Automated Production Lines 927
39.5 Cellular Manufacturing 931
39.6 Flexible Manufacturing Systems and Cells 935
39.7 Computer Integrated Manufacturing 939
Part XI Manufacturing Support Systems 945
40 MANUFACTURING ENGINEERING 945
40.1 Process Planning 946
40.2 Problem Solving and Continuous
Improvement 953
40.3 Concurrent Engineering and Design
for Manufacturability 954
41 PRODUCTION PLANNING AND
CONTROL 959
41.1 Aggregate Planning and the Master Production
Schedule 960
41.2 Inventory Control 962
41.3 Material and Capacity Requirements
Planning 965
41.4 Just-In-Time and Lean Production 969
41.5 Shop Floor Control 971
42 QUALITY CONTROL AND
INSPECTION 977
42.1 Product Quality 977
42.2 Process Capability and Tolerances 978
42.3 Statistical Process Control 980
42.4 Quality Programs in Manufacturing 984
42.5 Inspection Principles 990
42.6 Modern Inspection Technologies 992

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