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.
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