Manufacturing Engineering and Technology, Global Edition

About our authors Serope Kalpakjian is professor emeritus of Mechanical and Materials Engineering at the Illinois Institute of Technology.  He is the author of Mechanical Processing of Materials and co-author of Lubricants and Lubrication in Metalworking Operations (with E.S. Nachtman); the first editions of those textbooks have received the M. Eugene Merchant Manufacturing Textbook Award. He has conducted research in various areas of manufacturing, is the author of numerous technical papers and articles in handbooks and encyclopedias, and has edited a number of conference proceedings. He also has been editor and co-editor of several technical journals and has served on various editorial boards, including the Encyclopedia Americana.Among various awards, Professor Kalpakjian has received the Forging Industry Educational and Research Foundation Best Paper Award, the Excellence in Teaching Award from IIT, the ASME Centennial Medallion, the International Education Award from SME, A Person of the Millennium Award from lIT, the Albert Easton White Outstanding Teacher Award from ASM International, and the 2016 SME Gold Medal Award. For 2001, Outstanding Young Manufacturing Engineer Award of SME was named after him. Professor Kalpakjian is a Life Fellow ASME, Fellow SME, Fellow and Life Member ASM International, Fellow Emeritus International Academy for Production Engineering (CIRP), and is a founding member and past president of NAMRI. He is a graduate of Robert College (High Honor, Istanbul), Harvard University, and the Massachusetts Institute of Technology.Steven R. Schmid is the Belk-Woodward Distinguished Professor of Mechanical Engineering at the University of North Carolina - Charlotte, where he teaches and conducts research in the general areas of manufacturing, machine design and tribology. He previously spent almost 30 years on the faculty at the University of Notre Dame. He received his B.S. degree from Illinois Institute of Technology (with Honors) and Master's and Ph.D. from Northwestern University, all in mechanical engineering. He has received numerous awards, including the David Dornfeld Manufacturing Innovation Award and John T. Parsons Awards from SME, the Newkirk Award from ASME, the Kaneb Center Teaching Award (3 times), and the Ruth and Joel Spira Award for Excellence in Teaching.  He received the SME Gold Medal in 2022 and a lifetime achievement award from the Spanish manufacturing organization MESIC.Professor Schmid served as President of the North American Manufacturing Research Institution (NAMRI, 2015-2016) and was appointed the first Academic Fellow at the Advanced Manufacturing National Program Office, U.S. Department of Commerce, where he helped design the Manufacturing USA program. From 2016 to 2018, he served as the Program Director of the Manufacturing Machines and Equipment program and Head of the Advanced Manufacturing Cluster at the National Science Foundation. Dr. Schmid is the author of over 140 technical papers, and has co-authored Fundamentals of Machine Elements, Fundamentals of Fluid Film Lubrication, Schey's Tribology in Metalworking, Manufacturing Processes for Engineering Materials, and Manufacturing Engineering and Technology. He is a Fellow of the American Society of Mechanical Engineers and the Society of Manufacturing Engineers.

• NOTE: Each chapter concludes with Summary, Bibliography, Review Questions, Qualitative Problems, Quantitative Problems, Synthesis, Design, and Projects. I: Fundamentals of Materials: Behavior and Manufacturing Properties 1: The Structure of Metals1.1: 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 Growth1.8: Cold, Warm, and Hot Working 2: Mechanical Behavior, Testing, and Manufacturing Properties of Materials2.1: Introduction2.2: Tension2.3: Compression2.4: Torsion2.5: Bending (Flexure)2.6: Hardness2.7: Fatigue2.8: Creep2.9: Impact2.10: Failure and Fracture of Materials2.11: Residual Stresses2.12: Work, Heat, and Temperature 3: Physical Properties of Materials3.1: Introduction3.2: Density3.3: Melting Point3.4: Specific Heat3.5: Thermal Conductivity3.6: Thermal Expansion3.7: Electrical, Magnetic, and Optical Properties3.8 : Corrosion Resistance 4: Metal Alloys: Their Structure and Strengthening by Heat Treatment4.1: Introduction4.2: Structure of Alloys4.3: Phase Diagrams4.4: The Iron–Carbon System4.5: The Iron–Iron-carbide Phase Diagram and the Development of Microstructures in Steels4.6: Cast Irons4.7: Heat Treatment of Ferrous Alloys4.8: Hardenability of Ferrous Alloys4.9: Heat Treatment of Nonferrous Alloys and Stainless Steels4.10: Case Hardening4.11: Annealing4.12: Heat Treating Furnaces and Equipment4.13: Design Considerations for Heat Treating 5: Ferrous Metals and Alloys: Production, General Properties, and Applications5.1: Introduction5.2: Production of Iron and Steel5.3: Casting of Ingots5.4: Continuous Casting5.5: Carbon and Alloy Steels5.6: Stainless Steels5.7: Tool and Die Steels 6: Nonferrous Metals and Alloys: Production, General Properties, and Applications6.1: Introduction6.2: Aluminum and Aluminum Alloys6.3: Magnesium and Magnesium Alloys6.4: Copper and Copper Alloys6.5: Nickel and Nickel Alloys6.6: Superalloys6.7: Titanium and Titanium Alloys6.8: Refractory Metals and Alloys6.9: Beryllium6.10: Zirconium6.11: Lithium6.12: Low-melting Alloys6.13: Precious Metals6.14: Shape-memory Alloys (Smart Materials)6.15: Amorphous Alloys (Metallic Glasses)6.16: Metal Foams and Metamaterials6.17: Rare Earth Metals 7: Polymers: Structure, General Properties, and Applications7.1: Introduction7.2: The Structure of Polymers7.3: Thermoplastics7.4: Thermosetting Plastics7.5: Additives in Plastics7.6: General Properties and Applications of Thermoplastics7.7: General Properties and Applications of Thermosetting Plastics7.8: Biodegradable Plastics7.9: Elastomers (Rubbers)7.10: Gels 8: Ceramics, Glass, Graphite, Diamond, and Nanomaterials: Structure, General Properties, and Applications8.1: Introduction8.2: The Structure of Ceramics8.3: General Properties and Applications of Ceramics8.4: Glasses8.5: Glass Ceramics8.6: Graphite8.7: Diamond8.8: Nanomaterials 9: Composite Materials: Structure, General Properties, and Applications9.1: Introduction9.2: The Structure of Reinforced Plastics9.3: Properties of Reinforced Plastics9.4: Applications of Reinforced Plastics9.5: Metal-matrix Composites9.6: Ceramic-matrix Composites9.7: Other Composites II: Metal-casting Processes and Equipment 10: Fundamentals of Metal Casting10.1: Introduction10.2: Solidification of Metals10.3: Fluid Flow10.4: Fluidity of Molten Metal10.5: Heat Transfer10.6: Defects 11: Metal-casting Processes and Equipment11.1: Introduction11.2: Expendable-mold, Permanent-pattern Casting Processes11.3: Expendable-mold, Expendable-pattern Casting Processes11.4: Permanent-mold Casting Processes11.5: Casting Techniques for Single-crystal Components11.6: Rapid Solidification11.7: Inspection of Castings11.8: Melting Practice and Furnaces11.9: Foundries and Foundry Automation 12: Metal Casting: Design, Materials, and Economics12.1: Introduction12.2: Design Considerations in Casting12.3: Casting Alloys12.4: Economics of Casting III: Forming and Shaping Processes and Equipment 13: Metal-rolling Processes and Equipment13.1: Introduction13.2: The Flat-rolling Process13.3: Flat-rolling Practice13.4: Rolling Mills13.5: Various Rolling Processes and Mills 14: Metal-forging Processes and Equipment14.1: Introduction14.2: Open-die Forging14.3: Impression-die and Closed-die Forging14.4: Various Forging Operations14.5: Forgeability of Metals; Forging Defects14.6: Die Design, Die Materials, and Lubrication14.7: Die-manufacturing Methods and Die Failures14.8: Forging Machines14.9: Economics of Forging 15: Metal Extrusion and Drawing Processes and Equipment15.1: Introduction15.2: The Extrusion Process15.3: Hot Extrusion15.4: Cold Extrusion15.5: Extrusion Defects15.6: Design Considerations15.7: Extrusion Equipment15.8: The Drawing Process15.9: Drawing Practice15.10: Drawing Defects and Residual Stresses15.11: Drawing Equipment 16 : Sheet-Metal Forming Processes and Equipment16.1: Introduction16.2: Shearing16.3: Sheet-metal Characteristics and Formability16.4: Formability Tests for Sheet Metals16.5: Bending Sheets, Plates, and Tubes16.6: Miscellaneous Bending and Related Forming Operations16.7: Deep Drawing16.8: Rubber Forming and Hydroforming16.9: Spinning16.10: Superplastic Forming16.11: Hot Stamping16.12: Specialized Forming Processes16.13: Manufacturing of Metal Honeycomb Structures16.14: Design Considerations in Sheet-metal Forming16.15: Equipment for Sheet-metal Forming16.16: Economics of Sheet-forming Operations 17: Powder-Metal Processes and Equipment17.1: Introduction17.2: Production of Metal Powders17.3: Compaction of Metal Powders17.4: Sintering17.5: Secondary and Finishing Operations17.6: Design Considerations17.7: Economics of Powder Metallurgy 18: Ceramics, Glasses, and Superconductors: Processing and Equipment18.1: Introduction18.2: Shaping Ceramics18.3: Forming and Shaping of Glass18.4: Techniques for Strengthening and Annealing Glass18.5: Design Considerations for Ceramics and Glasses18.6: Processing of Superconductors 19: Plastics and Composite Materials: Forming and Shaping19.1: Introduction19.2: Extrusion19.3: Injection Molding19.4: Blow Molding19.5: Rotational Molding19.6: Thermoforming19.7: Compression Molding19.8: Transfer Molding19.9: Casting19.10: Foam Molding19.11: Cold Forming and Solid-phase Forming19.12: Processing Elastomers19.13: Processing Polymer-Matrix Composites19.14: Processing Metal-Matrix and Ceramic-Matrix Composites19.15: Design Considerations19.16: Economics of Processing Plastics and Composite Materials 20: Additive Manufacturing20.1: Introduction20.2: Additive Manufacturing Methodology20.3: Material Extrusion20.4: Vat Polymerization20.5: Material Jetting20.6: Binder Jetting20.7: Powder Bed Fusion20.8: Sheet Lamination20.9: Directed Energy Deposition20.10: Miscellaneous Processes20.11: Direct Manufacturing and Rapid Tooling20.12: Design for Additive Manufacturing20.13: Additive Manufacturing Economics IV: Machining Processes and Machine Tools 21: Fundamentals of Machining21.1: Introduction21.2: Mechanics of Cutting21.3: Cutting Forces and Power21.4: Temperatures in Cutting21.5: Tool Life: Wear and Failure21.6: Surface Finis21.7: Machinability 22: Cutting-Tool Materials and Cutting Fluids22.1: Introduction22.2: High-speed Steels22.3: Cast-cobalt Alloys22.4: Carbides22.5: Coated Tools22.6: Alumina-based Ceramics22.7: Cubic Boron Nitride22.8: Silicon-Nitride-based Ceramics22.9: Diamond22.10: Whisker-reinforced Materials and Nanomaterials22.11: Tool Costs and Reconditioning of Tools22.12: Cutting Fluids 23: Machining Processes: Turning and Hole Making23.1: Introduction23.2: The Turning Process23.3: Lathes and Lathe Operations23.4: Boring and Boring Machines23.5: Drilling, Drills, and Drilling Machines23.6: Reaming and Reamers23.7: Tapping and Taps 24: Machining Processes: Milling, Broaching, Sawing, Filing, and Gear Manufacturing24.1: Introduction24.2: Milling and Milling Machines24.3: Planing and Shaping24.4: Broaching and Broaching Machines24.5: Sawing24.6: Filing24.7: Gear Manufacturing by Machining 25: Machining Centers, Machine-tool Structures, and Machining25.1: Introduction25.2: Machining Centers25.3: Machine-tool Structures25.4: Vibration and Chatter in Machining Operations25.5: High-speed Machining25.6: Hard Machining25.7: Ultraprecision Machining25.8: Machining Economics 26: Abrasive Machining and Finishing Operations26.1: Introduction26.2: Abrasives and Bonded Abrasives26.3: The Grinding Process26.4: Grinding Operations and Machines26.5: Design Considerations for Grinding26.6: Ultrasonic Machining26.7: Finishing Operations26.8: Deburring Operations26.9: Economics of Abrasive Machining and Finishing Operations 27: Advanced Machining Processes27.1: Introduction27.2: Chemical Machining27.3: Electrochemical Machining27.4: Electrochemical Grinding27.5: Electrical-Discharge Machining27.6: Laser-beam Machining27.7: Electron-beam Machining27.8: Water-jet Machining27.9: Abrasive-jet Machining27.10: Hybrid Machining Systems V: Micromanufacturing and Fabrication of Microelectronic Devices 28: Fabrication of Microelectronic Devices28.1: Introduction28.2: Clean Rooms28.3: Semiconductors and Silicon28.4: Crystal Growing and Wafer Preparation28.5: Film Deposition28.6: Oxidation28.7: Lithography28.8: Etching28.9: Diffusion and Ion Implantation28.10: Metallization and Testing28.11: Wire Bonding and Packaging28.12: Yield and Reliability28.13: Printed Circuit Boards28.14: Roll-to-Roll Printing of Flexible Electronics28.15: Flexible Hybrid Electronics 29: Fabrication of Microelectromechanical Devices and Systems and Nanoscale Manufacturing29.1: Introduction29.2: Micromachining of MEMS Devices29.3: Electroforming-based Processes29.4: Solid Free-form Fabrication of Devices29.5: Mesoscale Manufacturing29.6: Nanoscale Manufacturing VI: Joining Processes and Equipment 30: Fusion Welding Processes30.1: Introduction30.2: Oxyfuel–Gas Welding30.3: Arc-welding Processes: Nonconsumable Electrode30.4: Arc-welding Processes: Consumable Electrode30.5: Electrodes for Arc Welding30.6: Electron-beam Welding30.7: Laser-beam Welding30.8: Cutting30.9: The Weld Joint, Quality and Testing30.10: Joint Design and Process Selection 31: Solid-state Welding Processes31.1: Introduction31.2: Cold Welding and Roll Bonding31.3: Ultrasonic Welding31.4: Friction Welding31.5: Resistance Welding31.6: Explosion Welding31.7: Diffusion Bonding31.8: Economics of Welding Operations 32: Brazing, Soldering, Adhesive-bonding, and Mechanical Fastening Processes32.1: Introduction32.2: Brazing32.3: Soldering32.4: Adhesive Bonding32.5: Mechanical Fastening32.6: Joining Plastics, Ceramics, and Glasses32.7: Economics of Joining Operations VII: Surface Technology 33: Surface Roughness and Measurement; Friction, Wear, and Lubrication33.1: Introduction33.2: Surface Structure and Integrity33.3: Surface Texture and Roughness33.4: Friction33.5: Wear33.6: Lubrication33.7: Metalworking Fluids and Their Selection 34: Surface Treatments, Coatings, and Cleaning34.1: Introduction34.2: Mechanical Surface Treatments34.3: Mechanical Plating and Cladding34.4: Case Hardening and Hard Facing34.5: Thermal Spraying34.6: Vapor Deposition34.7: Ion Implantation and Diffusion Coating34.8: Laser Treatments34.9: Electroplating, Electroless Plating, and Electroforming34.10: Conversion Coatings34.11: Hot Dipping34.12: Porcelain Enameling; Ceramic and Organic Coatings34.13: Diamond Coating and Diamondlike Carbon34.14: Surface Texturing34.15: Painting34.16: Cleaning of Surfaces VIII: Engineering Metrology, Instrumentation, and Quality Assurance 35: Engineering Metrology and Instrumentation35.1: Introduction35.2: Measurement Standards35.3: Geometric Features of Parts: Analog and Digital Measurements35.4: Traditional Measuring Methods and Instruments35.5: Modern Measuring Instruments and Machines35.6: Automated Measurement35.7: General Characteristics and Selection of Measuring Instruments35.8: Geometric Dimensioning and Tolerancing 36: Quality Assurance, Testing, and Inspection36.1: Introduction36.2: Product Quality36.3: Quality Assurance36.4: Total Quality Management36.5: Taguchi Methods36.6: The ISO and QS Standards36.7: Statistical Methods of Quality Control36.8: Statistical Process Control36.9: Reliability of Products and Processes36.10: Nondestructive Testing36.11: Destructive Testing36.12: Automated Inspection IX: Manufacturing in a Competitive Environment 37: Automation of Manufacturing Processes and Operations37.1: Introduction37.2: Automation37.3: Numerical Control37.4: Adaptive Control37.5: Material Handling and Movement37.6: Industrial Robots37.7: Sensor Technology37.8: Flexible Fixturing37.9: Assembly Systems37.10: Design Considerations for Fixturing, Assembly, Disassembly, and Servicing37.11: Economic Considerations 38: Computer-aided Manufacturing38.1: Introduction38.2: Manufacturing Systems38.3: Computer-integrated Manufacturing38.4: Computer-aided Design and Engineering38.5: Computer-aided Manufacturing38.6: Computer-aided Process Planning38.7: Computer Simulation of Manufacturing Processes and Systems38.8: Group Technology 39: Computer-integrated Manufacturing Systems39.1: Introduction39.2: Cellular Manufacturing39.3: Flexible Manufacturing Systems39.4: Mass Customization39.5: Holonic Manufacturing39.6: Just-in-time Production39.7: Lean Manufacturing39.8: Communications Networks in Manufacturing39.9: Artificial Intelligence and Machine Learning39.10: Economic Considerations 40: Product Design and Manufacturing in a Competitive Environment 40.1: Introduction40.2: Product Design40.3: Product Quality40.4: Decarbonization and Sustainable Manufacturing40.5: Energy Consumption in Manufacturing40.6: Material Selection for Products40.7: Material Substitution40.8: Manufacturing Process Capabilities40.9: Process Selection40.10: Manufacturing Costs and Cost Reduction Index