DeGarmo's Materials and Processes in Manufacturing, Global Edition

Häftad, Engelska, 2018

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Beskrivning

Newly revised, DeGarmo's Materials and Processes in Manufacturing has been the market-leading text on manufacturing and manufacturing processes courses for over fifty years. Authors J T. Black and Ron Kohser have continued this book's long and distinguished tradition of exceedingly clear presentation and highly practical approach to materials and processes, presenting mathematical models and analytical equations only when they enhance the basic understanding of the material. Updated to reflect all current practices, standards, and materials, this edition has new coverage of additive manufacturing, lean engineering, and processes related to ceramics, polymers, and plastics.

Produktinformation

Utgivningsdatum:2018-01-19
Mått:10 x 10 x 10 mm
Vikt:454 g
Format:Häftad
Språk:Engelska
Antal sidor:804
Upplaga:12
Förlag:John Wiley & Sons Inc
ISBN:9781119382898

Utforska kategorier

Maskinteknik och material inom Naturvetenskap och teknik

Innehållsförteckning

Preface iii1 Introduction to DeGarmo’s Materials and Processes in Manufacturing 11.1 Materials, Manufacturing, and the Standard of Living 11.2 Manufacturing and Production Systems 3Review Questions 24Problems 252 Properties of Materials 262.1 Introduction 262.2 Static Properties 282.3 Dynamic Properties 382.4 Temperature Effects (Both High and Low) 432.5 Machinability, Formability, and Weldability 462.6 Fracture Toughness and the Fracture Mechanics Approach 462.7 Physical Properties 482.8 Testing Standards and Testing Concerns 48Review Questions 48Problems 503 Nature of Materials 513.1 Structure—Property—Processing—Performance Relationships 513.2 The Structure of Atoms 523.3 Atomic Bonding 523.4 Secondary Bonds 533.5 Atom Arrangements in Materials 543.6 Crystal Structures 543.7 Development of a Grain Structure 563.8 Elastic Deformation 563.9 Plastic Deformation 573.10 Dislocation Theory of Slippage 583.11 Strain Hardening or Work Hardening 593.12 Plastic Deformation in Polycrystalline Material 603.13 Grain Shape and Anisotropic Properties 603.14 Fracture 613.15 Cold Working, Recrystallization, and Hot Working 613.16 Grain Growth 623.17 Alloys and Alloy Types 623.18 Atomic Structure and Electrical Properties 62Review Questions 63Problems 644 Equilibrium Phase Diagrams and the Iron–Carbon System 654.1 Introduction 654.2 Phases 654.3 Equilibrium Phase Diagrams 654.4 Iron–Carbon Equilibrium Diagram 714.5 Steels and the Simplified Iron–Carbon Diagram 724.6 Cast Irons 74Review Questions 75Problems 765 Heat Treatment 775.1 Introduction 775.2 Processing Heat Treatments 775.3 Heat Treatments Used to Increase Strength 805.4 Strengthening Heat Treatments for Nonferrous Metals 805.5 Strengthening Heat Treatments for Steel 835.6 Surface Hardening of Steel 945.7 Furnaces 965.8 Heat Treatment and Energy 97Review Questions 98Problems 996 Ferrous Metals and Alloys 1016.1 Introduction to History-Dependent Materials 1016.2 Ferrous Metals 1016.3 Iron 1026.4 Steel 1026.5 Stainless Steels 1136.6 Tool Steels 1156.7 Cast Irons 1176.8 Cast Steels 1206.9 The Role of Processing on Cast Properties 120Review Questions 121Problems 1227 Nonferrous Metals and Alloys 1237.1 Introduction 1237.2 Copper and Copper Alloys 1237.3 Aluminum and Aluminum Alloys 1287.4 Magnesium and Magnesium Alloys 1347.5 Zinc and Zinc Alloys 1367.6 Titanium and Titanium Alloys 1377.7 Nickel-Based Alloys 1387.8 Superalloys, Refractory Metals, and Other Materials Designed for High-Temperature Service 1387.9 Lead and Tin and Their Alloys 1417.10 Some Lesser-Known Metals and Alloys 1417.11 Metallic Glasses 1417.12 Graphite 1427.13 Materials for Specific Applications 1427.14 High Entropy Alloys 142Review Questions 143Problems 1448 Nonmetallic Materials: Plastics, Elastomers, Ceramics, and Composites 1458.1 Introduction 1458.2 Plastics 1458.3 Elastomers 1568.4 Ceramics 1598.5 Composite Materials 166Review Questions 174Problems 1759 Material Selection 1779.1 Introduction 1779.2 Material Selection and Manufacturing Processes 1799.3 The Design Process 1799.4 Approaches to Material Selection 1809.5 Additional Factors to Consider 1839.6 Consideration of the Manufacturing Process 1839.7 Ultimate Objective 1849.8 Materials Substitution 1859.9 Effect of Product Liability on Materials Selection 1869.10 Aids to Material Selection 186Review Questions 187Problems 18810 Fundamentals of Casting 19110.1 Introduction to Materials Processing 19110.2 Introduction to Casting 19210.3 Casting Terminology 19310.4 The Solidification Process 19410.5 Patterns 20210.6 Design Considerations in Castings 20310.7 The Casting Industry 206Review Questions 206Problems 20811 Expendable-Mold Casting Processes 20911.1 Introduction 20911.2 Sand Casting 20911.3 Cores and Core Making 22211.4 Other Expendable-Mold Processes with Multiple-Use Patterns 22511.5 Expendable-Mold Processes Using Single-Use Patterns 22611.6 Shakeout, Cleaning, and Finishing 23211.7 Summary 232Review Questions 232Problems 23412 Multiple-Use-Mold Casting Processes 23512.1 Introduction 23512.2 Permanent-Mold Casting 23512.3 Die Casting 23812.4 Squeeze Casting and Semisolid Casting 24112.5 Centrifugal Casting 24212.6 Continuous Casting 24412.7 Melting 24412.8 Pouring Practice 24712.9 Cleaning, Finishing, Heat Treating, and Inspection 24712.10 Automation in Foundry Operations 24812.11 Process Selection 248Review Questions 250Problems 25113 Fabrication of Plastics, Ceramics, and Composites 25213.1 Introduction 25213.2 Fabrication of Plastics 25213.3 Processing of Rubber and Elastomers 26213.4 Processing of Ceramics 26313.5 Fabrication of Composite Materials 267Review Questions 275Problems 27714 Fundamentals of Metal Forming 27914.1 Introduction 27914.2 Forming Processes: Independent Variables 28014.3 Dependent Variables 28114.4 Independent–Dependent Relationships 28114.5 Process Modeling 28214.6 General Parameters 28214.7 Friction, Lubrication, and Wear under Metalworking Conditions 28314.8 Temperature Concerns 28414.9 Formability 290Review Questions 290Problems 29215 Bulk Forming Processes 29315.1 Introduction 29315.2 Classification of Deformation Processes 29315.3 Bulk Deformation Processes 29415.4 Rolling 29415.5 Forging 29815.6 Extrusion 30815.7 Wire, Rod, and Tube Drawing 31215.8 Cold Forming, Cold Forging, and Impact Extrusion 31415.9 Piercing 31715.10 Other Squeezing Processes 31815.11 Surface Improvement by Deformation Processing 320Review Questions 321Problems 32216 Sheet-Forming Processes 32516.1 Introduction 32516.2 Shearing Operations 32516.3 Bending 33116.4 Drawing and Stretching Processes 33816.5 Alternative Methods of Producing Sheet-Type Products 34916.6 Seamed Pipe Manufacture 34916.7 Presses 350Review Questions 354Problems 35617 Powder Metallurgy (Particulate Processing) 35717.1 Introduction 35717.2 The Basic Process 35717.3 Powder Manufacture 35817.4 Powder Testing and Evaluation 35917.5 Powder Mixing and Blending 36017.6 Compacting 36017.7 Sintering 36317.8 Advances in Sintering (Shorter Time, Higher Density, Stronger Products) 36417.9 Hot-Isostatic Pressing 36517.10 Other Techniques to Produce High-Density P/M Products 36617.11 Metal Injection Molding (MIM) 36617.12 Secondary Operations 36817.13 Properties of P/M Products 36917.14 Design of Powder Metallurgy Parts 37117.15 Powder Metallurgy Products 37117.16 Advantages and Disadvantages of Powder Metallurgy 37317.17 Process Summary 374Review Questions 375Problems 37618 Additive Processes—Including 3-D Printing 37718.1 Introduction 37718.2 Layerwise Manufacturing 37818.3 Liquid-Based Processes 38118.4 Powder-Based Processes 38318.5 Deposition-Based Processes 38718.6 Uses and Applications 39018.7 Pros, Cons and Current and Future Trends 39318.8 Economic Considerations 395Review Questions 396Problems 39719 Fundamentals of Machining/ Orthogonal Machining 39819.1 Introduction 39819.2 Fundamentals 39819.3 Forces and Power in Machining 40619.4 Orthogonal Machining (Two Forces) 40919.5 Chip Thickness Ratio, rc 41219.6 Mechanics of Machining (Statics) 41319.7 Shear Strain, γ, and Shear Front Angle, ϕ 41419.8 Mechanics of Machining (Dynamics) (Section courtsey of Dr. Elliot Stern) 416Review Questions 422Problems 42320 Cutting Tool Materials 42420.1 Introduction 42420.2 Cutting Tool Materials 42820.3 Tool Geometry 43720.4 Tool-Coating Processes 43820.5 Tool Failure and Tool Life 44020.6 Taylor Tool Life 44120.7 Cutting Fluids 44620.8 Economics of Machining 446Review Questions 448Problems 44921 Turning and Boring Processes 45121.1 Introduction 45121.2 Fundamentals of Turning, Boring, and Facing Turning 45321.3 Lathe Design and Terminology 45721.4 Cutting Tools for Lathes 46221.5 Workholding in Lathes 466Review Questions 470Problems 47122 Milling 47222.1 Introduction 47222.2 Fundamentals of Milling Processes 47222.3 Milling Tools and Cutters 47922.4 Machines for Milling 483Review Questions 487Problems 48723 Drilling and Related Hole-Making Processes 48823.1 Introduction 48823.2 Fundamentals of the Drilling Process 48923.3 Types of Drills 49023.4 Tool Holders for Drills 50023.5 Workholding for Drilling 50123.6 Machine Tools for Drilling 50123.7 Cutting Fluids for Drilling 50423.8 Counterboring, Countersinking, and Spot Facing 50623.9 Reaming 506Review Questions 508Problems 50924 Sawing, Broaching, Shaping, and Filing Machining Processes 51024.1 Introduction 51024.2 Introduction to Sawing 51024.3 Introduction to Broaching 51824.4 Fundamentals of Broaching 52024.5 Broaching Machines 52524.6 Introduction to Shaping and Planing 52524.7 Introduction to Filing 529Review Questions 531Problems 53225 Abrasive Machining Processes 53325.1 Introduction 53325.2 Abrasives 53525.3 Grinding Wheel Structure and Grade 53825.4 Grinding Wheel Identification 54225.5 Grinding Machines 54625.6 Honing 55325.7 Superfinishing 55425.8 Free Abrasives 55525.9 Design Considerations in Grinding 559Review Questions 559Problems 56026 CNC Processes and Adaptive Control: A(4) and A(5) Levels of Automation 56126.1 Introduction 56126.2 Basic Principles of Numerical Control 56126.3 CNC Part Programming 56726.4 Interpolation and Adaptive Control 57426.5 Machining Center Features and Trends 57726.6 Summary 581Review Questions 581Problems 58227 JIG and Fixture Design 58427.1 Introduction 58427.2 Conventional Fixture Design 58427.3 Tool Design Steps 58727.4 Clamping Considerations 58827.5 Chip Disposal 58927.6 Example of Jig Design 58927.7 Types of Jigs 59127.8 Conventional Fixtures 59327.9 Modular Fixturing 59327.10 Setup and Changeover 59427.11 Clamps 59927.12 Other Workholding Devices 59927.13 Economic Justification of Jigs and Fixtures 602Review Questions 603Problems 60328 Nontraditional Manufacturing Processes 60528.1 Introduction 60528.2 Chemical Machining Processes 60728.3 Electrochemical Machining Processes 61128.4 Electrical Discharge Machining 616Review Questions 62429 Fundamentals of Joining 62629.1 Introduction to Consolidation Processes 62629.2 Classification of Welding and Thermal Cutting Processes 62729.3 Some Common Concerns 62729.4 Types of Fusion Welds and Types of Joints 62829.5 Design Considerations 63029.6 Heat Effects 63029.7 Weldability or Joinability 63529.8 Summary 635Review Questions 636Problems 63730 Gas Flame and Arc Processes 63830.1 Oxyfuel-Gas Welding 63830.2 Oxygen Torch Cutting 64130.3 Flame Straightening 64330.4 Arc Welding 64330.5 Consumable-Electrode Arc Welding 64430.6 Nonconsumable Electrode Arc Welding 65030.7 Other Processes Involving Arcs 65430.8 Arc Cutting 65630.9 Metallurgical and Heat Effects in Thermal Cutting 65830.10 Welding Equipment 65830.11 Thermal Deburring 659Review Questions 660Problems 66231 Resistance and Solid-State Welding Processes 66331.1 Introduction 66331.2 Theory of Resistance Welding 66331.3 Resistance Welding Processes 66531.4 Advantages and Limitations of Resistance Welding 66931.5 Solid-State Welding Processes 669Review Questions 677Problems 67832 Other Welding Processes, Brazing, and Soldering 67932.1 Introduction 67932.2 Other Welding and Cutting Processes 67932.3 Surface Modification by Welding-Related Processes 68632.4 Brazing 68932.5 Soldering 696Review Questions 699Problems 70033 Adhesive Bonding, Mechanical Fastening, and Joining of Non-Metals 70133.1 Adhesive Bonding 70133.2 Mechanical Fastening 70833.3 Joining of Plastics 71133.4 Joining of Ceramics and Glass 71333.5 Joining of Composites 714Review Questions 714Problems 71534 Surface Integrity and Finishing Processes 71734.1 Introduction 71734.2 Surface Integrity 71734.3 Abrasive Cleaning and Finishing 72434.4 Chemical Cleaning 72934.5 Coatings 73034.6 Vaporized Metal Coatings 73834.7 Clad Materials 73834.8 Textured Surfaces 73834.9 Coil-Coated Sheets 73834.10 Edge Finishing and Burr Removal 739Review Questions 74135 Nano and Micro-Manufacturing Processes 74235.1 Introduction 74235.2 Lithography 74535.3 Micromachining Processes 74835.4 Deposition Processes 75135.5 How ICs are Made 75735.6 Nano- and Micro-Scale Metrology 763Review Questions 765Problems 76636 Measurement and Inspection 767(online at www.wiley.com/college/black)36.1 Introduction 76736.2 Standards of Measurement 76736.3 Allowance and Tolerance 77036.4 Inspection Methods for Measurement 77636.5 Measuring Instruments 77736.6 Vision Systems 78436.7 Coordinate Measuring Machines 78536.8 Angle-measuring Instruments 78736.9 Gages for Attributes Measuring 787Review Questions 790Problems 79137 Nondestructive Examination (NDE) / Nondestructive Testing (NDT) 793(online at www.wiley.com/college/black)37.1 Destructive vs. Nondestructive Testing 79337.2 Visual Inspection 79537.3 Liquid Penetrant Inspection 79537.4 Magnetic Particle Inspection 79637.5 Ultrasonic Inspection 79737.6 Radiography 79937.7 Eddy-Current Testing 80037.8 Acoustic Emission Monitoring 80237.9 Other Methods of Nondestructive Testing and Inspection 80337.10 Dormant vs. Critical Flaws 80437.11 Current and Future Trends 804Review Questions 804Problems 80538 Manufacturing Automation and Industrial Robots 807(online at www.wiley.com/college/black)38.1 Introduction 80738.2 The A(4) Level of Automation 81238.3 A(5) Level of Automation Requires Evaluation 81838.4 Industrial Robotics 82238.5 Computer-Integrated Manufacturing (CIM) 82838.6 Computer-Aided Design 83038.7 Computer-Aided Manufacturing 83238.8 Summary 832Review Questions 833Advanced Topic 1 Process Capability and Quality Control 834(online at www.wiley.com/college/black)A1.1 Introduction 834A1.2 Determining Process Capability 835A1.3 Introduction to Statistical Quality Control 841A1.4 Sampling Errors 845A1.5 Gage Capability 846A1.6 Just in Time/Total Quality Control 846A1.7 Six Sigma 855A1.8 Summary 858Review Questions 858Problems 859Advanced Topic 2 The Enterprise (Production System) 861(online at www.wiley.com/college/black)A2.1 Introduction 861A2.2 Typical Functional Areas in the Production System (PS) 861Review Questions 876Problems 877Advanced Topic 3 Lean Engineering 878(online at www.wiley.com/college/black)A3.1 Introduction 878A3.2 The Lean Engineer 878A3.3 The Lean Production System 879A3.4 Linked-Cell Manufacturing System Design Rules 879A3.5 Manufacturing System Designs 880A3.6 Preliminary Steps to Lean Production 881A3.7 Methodology for Implementation of Lean Production 882A3.8 Design Rule MT