- ホーム
- > 洋書
- > 英文書
- > History / World
Full 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.
Contents
Preface v Chapter 1 Introduction to DeGarmo'sMaterials and Processes in Manufacturing 1 1.1 Materials, Manufacturing, and the Standardof Living 1 1.2 Manufacturing and Production Systems 3 Case Study Famous Manufacturing Engineers 28 Chapter 2 Manufacturing Systems Design 30 2.1 Introduction 30 2.2 Manufacturing Systems 30 2.3 Control of the Manufacturing System 32 2.4 Classification of Manufacturing Systems 33 2.5 Summary of Factory Designs 49 Case Study Jury Duty for an Engineer 58 Chapter 3 Properties of Materials 59 3.1 Introduction 59 3.2 Static Properties 61 3.3 Dynamic Properties 74 3.4 Temperature Effects (Both High and Low) 79 3.5 Machinability, Formability, and Weldability 83 3.6 Fracture Toughness and the Fracture Mechanics Approach 83 3.7 Physical Properties 85 3.8 Testing Standards and Testing Concerns 85 Case Study Separation of Mixed Materials 88 Chapter 4 Nature of Metals and Alloys 89 4.1 Structure-Property-Processing-Performance Relationships 89 4.2 The Structure of Atoms 90 4.3 Atomic Bonding 90 4.4 Secondary Bonds 92 4.5 Atom Arrangements in Materials 92 4.6 Crystal Structures of Metals 93 4.7 Development of a Grain Structure 94 4.8 Elastic Deformation 95 4.9 Plastic Deformation 96 4.10 Dislocation Theory of Slippage 97 4.11 Strain Hardening or Work Hardening 98 4.12 Plastic Deformation in Polycrystalline Metals 99 4.13 Grain Shape and Anisotropic Properties 100 4.14 Fracture of Metals 101 4.15 Cold Working, Recrystallization, and Hot Working 101 4.16 Grain Growth 102 4.17 Alloys and Alloy Types 102 4.18 Atomic Structure and Electrical Properties 103 Chapter 5 Equilibrium Phase Diagrams and the Iron-Carbon System 106 5.1 Introduction 106 5.2 Phases 106 5.3 Equilibrium Phase Diagrams 106 5.4 Iron-Carbon Equilibrium Diagram 114 5.5 Steels and the Simplified Iron-Carbon Diagram 116 5.6 Cast Irons 117 Case Study Fish Hooks 120 Chapter 6 Heat Treatment 121 6.1 Introduction 121 6.2 Processing Heat Treatments 122 6.3 Heat Treatments Used to Increase Strength 125 6.4 Strengthening Heat Treatments for Nonferrous Metals 125 6.5 Strengthening Heat Treatments for Steel 128 6.6 Surface Hardening of Steel 143 6.7 Furnaces 145 6.8 Heat Treatment and Energy 147 Case Study A Carpenter's Claw Hammer 150 Chapter 7 Ferrous Metals and Alloys 152 7.1 Introduction to History-Dependent Materials 152 7.2 Ferrous Metals 152 7.3 Iron 153 7.4 Steel 154 7.5 Stainless Steels 168 7.6 Tool Steels 171 7.7 Cast Irons 173 7.8 Cast Steels 178 7.9 The Role of Processing on Cast Properties 179 Case Study The Paper Clip 181 Chapter 8 Nonferrous Metals and Alloys 182 8.1 Introduction 182 8.2 Copper and Copper Alloys 183 8.3 Aluminum and Aluminum Alloys 188 8.4 Magnesium and Magnesium Alloys 196 8.5 Zinc and Zinc Alloys 198 8.6 Titanium and Titanium Alloys 199 8.7 Nickel-Based Alloys 201 8.8 Superalloys, Refractory Metals, and Other Materials Designed for High-Temperature Service 201 8.9 Lead and Tin, and Their Alloys 203 8.10 Some Lesser-Known Metals and Alloys 204 8.11 Metallic Glasses 204 8.12 Graphite 205 Case Study Hip Replacement Prosthetics 207 Chapter 9 Nonmetallic Materials: Plastics, Elastomers, Ceramics, and Composites 208 9.1 Introduction 208 9.2 Plastics 209 9.3 Elastomers 222 9.4 Ceramics 224 9.5 Composite Materials 234 Case Study Lightweight Armor 247 Chapter 10 Material Selection 248 10.1 Introduction 248 10.2 Material Selection and Manufacturing Processes 252 10.3 The Design Process 252 10.4 Approaches to Material Selection 253 10.5 Additional Factors to Consider 256 10.6 Consideration of the Manufacturing Process 258 10.7 Ultimate Objective 258 10.8 Materials Substitution 260 10.9 Effect of Product Liability on Materials Selection 261 10.10 Aids to Material Selection 262 Case Study Material Selection 266 Chapter 11 Fundamentals of Casting 267 11.1 Introduction to Materials Processing 267 11.2 Introduction to Casting 269 11.3 Casting Terminology 270 11.4 The Solidification Process 271 11.5 Patterns 281 11.6 Design Considerations in Castings 284 11.7 The Casting Industry 287 Case Study The Cast Oil-Field Fitting 290 Chapter 12 Expendable-Mold Casting Processes 291 12.1 Introduction 291 12.2 Sand Casting 292 12.3 Cores and Core Making 307 12.4 Other Expendable-Mold Processes with Multiple-Use Patterns 311 12.5 Expendable-Mold Processes Using Single-Use Patterns 313 12.6 Shakeout, Cleaning, and Finishing 320 12.7 Summary 320 Case Study Movable and Fixed Jaw Pieces for a Heavy-Duty Bench Vise 322 Chapter 13 Multiple-Use-Mold Casting Processes 323 13.1 Introduction 323 13.2 Permanent-Mold Casting 323 13.3 Die Casting 327 13.4 Squeeze Casting and Semisolid Casting 331 13.5 Centrifugal Casting 333 13.6 Continuous Casting 335 13.7 Melting 336 13.8 Pouring Practice 339 13.9 Cleaning, Finishing, and Heat Treating of Castings 339 13.10 Automation in Foundry Operations 341 13.11 Process Selection 341 Case Study Baseplate for a Household Steam Iron 344 Chapter 14 Fabrication of Plastics, Ceramics, and Composites 345 14.1 Introduction 345 14.2 Fabrication of Plastics 345 14.3 Processing of Rubber and Elastomers 359 14.4 Processing of Ceramics 360 14.5 Fabrication of Composite Materials 364 Case Study Automotive and Light Truck Fuel Tanks 378 Chapter 15 Fundamentals of Metal Forming 379 15.1 Introduction 379 15.2 Forming Processes: Independent Variables 380 15.3 Dependent Variables 382 15.4 Independent-Dependent Relationships 382 15.5 Process Modeling 383 15.6 General Parameters 384 15.7 Friction and Lubrication Under Metalworking Conditions 385 15.8 Temperature Concerns 387 15.9 Formability 395 Case Study Interior Tub of a Top-Loading Washing Machine 397 Chapter 16 Bulk-Forming Processes 398 16.1 Introduction 398 16.2 Classification of Deformation Processes 398 16.3 Bulk Deformation Processes 399 16.4 Rolling 399 16.5 Forging 406 16.6 Extrusion 418 16.7 Wire, Rod, and Tube Drawing 424 16.8 Cold Forming, Cold Forging, and Impact Extrusion 427 16.9 Piercing 431 16.10 Other Squeezing Processes 432 16.11 Surface Improvement by Deformation Processing 434 Case Study Handle and Body of a Large Ratchet Wrench 439 Chapter 17 Sheet-Forming Processes 440 17.1 Introduction 440 17.2 Shearing Operations 440 17.3 Bending 449 17.4 Drawing and Stretching Processes 456 17.5 Alternative Methods of Producing Sheet-Type Products 471 17.6 Pipe Manufacture 472 17.7 Presses 472 Case Study Automotive Body Panels 480 Chapter 18 Powder Metallurgy 481 18.1 Introduction 481 18.2 The Basic Process 482 18.3 Powder Manufacture 483 18.4 Microcrystalline and Amorphous Material Produced by Rapid Cooling 484 18.5 Powder Testing and Evaluation 484 18.6 Powder Mixing and Blending 485 18.7 Compacting 485 18.8 Sintering 489 18.9 Recent Advances in Sintering 490 18.10 Hot-Isostatic Pressing 491 18.11 Other Techniques to Produce High-Density Powder Metallurgy Products 492 18.12 Metal Injection Molding or Powder Injection Molding 493 18.13 Secondary Operations 495 18.14 Properties of Powder Metallurgy Products 497 18.15 Design of Powder Metallurgy Parts 498 18.16 Powder Metallurgy Products 499 18.17 Advantages and Disadvantages of Powder Metallurgy 501 18.18 Process Summary 502 Case Study Steering Gear for a Riding Lawn Mower/Garden Tractor 506 Chapter 19 Additive Processes: Rapid Prototyping and Direct- Digital Manufacturing 507 19.1 Introduction 507 19.2 Rapid Prototyping and Direct-Digital Manufacturing 508 19.3 Layerwise Manufacturing 510 19.4 Liquid-Based Processes 514 19.5 Powder-Based Processes 517 19.6 Deposition-Based Processes 521 19.7 Uses and Applications 524 19.8 Pros, Cons, and Current and Future Trends 528 19.9 Economic Considerations 529 Chapter 20 Fundamentals of Machining/Orthogonal Machining 533 20.1 Introduction 533 20.2 Fundamentals 533 20.3 Forces and Power in Machining 541 20.4 Orthogonal Machining (Two Forces) 547 20.5 Chip Thickness Ratio, rc 551 20.6 Mechanics of Machining (Statics) 553 20.7 Shear Strain, g, and Shear Front Angle, w 555 20.8 Mechanics of Machining (Dynamics) 557 20.9 Summary 564 Case Study Orthogonal Plate Machining Experiment at Auburn University 568 Chapter 21 Cutting Tools for Machining 569 21.1 Introduction 569 21.2 Cutting Tool Materials 573 21.3 Tool Geometry 587 21.4 Tool-Coating Processes 589 21.5 Tool Failure and Tool Life 592 21.6 Flank Wear 593 21.7 Cutting Fluids 599 21.8 Economics of Machining 600 Case Study Comparing Tool Materials Based on Tool Life 608 Chapter 22 Turning and Boring Processes 609 22.1 Introduction 609 22.2 Fundamentals of Turning, Boring, and Facing Turning 611 22.3 Lathe Design and Terminology 617 22.4 Cutting Tools for Lathes 625 22.5 Workholding in Lathes 629 Case Study Estimating the Machining Time for Turning 636 Chapter 23 Drilling and Related Hole-Making Processes 637 23.1 Introduction 637 23.2 Fundamentals of the Drilling Process 638 23.3 Types of Drills 640 23.4 Tool Holders for Drills 652 23.5 Workholding for Drilling 654 23.6 Machine Tools for Drilling 654 23.7 Cutting Fluids for Drilling 657 23.8 Counterboring, Countersinking, and Spot Facing 659 23.9 Reaming 659 Case Study Bolt-down Leg on a Casting 664 Chapter 24 Milling 665 24.1 Introduction 665 24.2 Fundamentals of Milling Processes 665 24.3 Milling Tools and Cutters 672 24.4 Machines for Milling 678 Case Study HSS versus Tungsten Carbide Milling 685 Chapter 25 Sawing, Broaching, and Other Machining Processes 686 25.1 Introduction 686 25.2 Introduction to Sawing 686 25.3 Introduction to Broaching 694 25.4 Fundamentals of Broaching 695 25.5 Broaching Machines 703 25.6 Introduction to Shaping and Planing 704 25.7 Introduction to Filing 709 Case Study Cost Estimating-Planing vs. Milling 713 Chapter 26 Abrasive Machining Processes 714 26.1 Introduction 714 26.2 Abrasives 715 26.3 Grinding Wheel Structure and Grade 721 26.4 Grinding Wheel Identification 726 26.5 Grinding Machines 730 26.6 Honing 738 26.7 Superfinishing 740 26.8 Free Abrasives 742 26.9 Design Considerations In Grinding 746 Case Study Process Planning for the MfE 748 Chapter 27 Workholding Devices for Machine Tools 749 27.1 Introduction 749 27.2 Conventional Fixture Design 749 27.3 Tool Design Steps 752 27.4 Clamping Considerations 753 27.5 Chip Disposal 755 27.6 Unloading and Loading Time 756 27.7 Example of Jig Design 756 27.8 Types of Jigs 758 27.9 Conventional Fixtures 759 27.10 Modular Fixturing 761 27.11 Setup and Changeover 763 27.12 Clamps 765 27.13 Other Workholding Devices 766 27.14 Economic Justification of Jigs and Fixtures 769 Case Study Fixture versus No Fixture in Milling 774 Chapter 28 Nontraditional Manufacturing Processes 775 28.1 Introduction 775 28.2 Chemical Machining Processes 777 28.3 Electrochemical Machining Processes 783 28.4 Electrical Discharge Machining 790 Case Study Vented Cap Screws 802 Chapter 29 Lean Engineering 803 29.1 Introduction 803 29.2 The Lean Engineer 803 29.3 The Lean Production System 804 29.4 Linked-Cell Manufacturing System Design Rules 804 29.5 Manufacturing System Designs 806 29.6 Preliminary Steps to Lean Production 808 29.7 Methodology for Implementation of Lean Production 808 29.8 Design Rule MT < CT 823 29.9 Decouplers 825 29.10 Integrating Production Control 828 29.11 Integrating Inventory Control 832 29.12 Lean Manufacturing Cell Design 833 29.13 Machine Tool Design for Lean Manufacturing Cells 838 29.14 L-CMS Strategy 841 Case Study Cycle Time for a Manufacturing Cell 844 Chapter 30 Fundamentals of Joining 845 30.1 Introduction to Consolidation Processes 845 30.2 Classification of Welding and Thermal Cutting Processes 846 30.3 Some Common Concerns 847 30.4 Types of Fusion Welds and Types of Joints 847 30.5 Design Considerations 850 30.6 Heat Effects 850 30.7 Weldability or Joinability 857 30.8 Summary 858 Chapter 31 Gas Flame and Arc Processes 860 31.1 Oxyfuel-Gas Welding 860 31.2 Oxygen Torch Cutting 864 31.3 Flame Straightening 866 31.4 Arc Welding 867 31.5 Consumable-Electrode Arc Welding 869 31.6 Nonconsumable-Electrode Arc Welding 877 31.7 Welding Equipment 882 31.8 Arc Cutting 884 31.9 Metallurgical and Heat Effects in Thermal Cutting 886 Case Study Bicycle Frame Construction and Repair 888 Chapter 32 Resistance- and Solid-State Welding Processes 890 32.1 Introduction 890 32.2 Theory of Resistance Welding 890 32.3 Resistance-Welding Processes 893 32.4 Advantages and Limitations of Resistance Welding 898 32.5 Solid-State Welding Processes 899 Case Study Manufacture of an Automobile Muffler 909 Chapter 33 Other Welding Processes, Brazing, and Soldering 910 33.1 Introduction 910 33.2 Other Welding and Cutting Processes 910 33.3 Surface Modification by Welding-Related Processes 919 33.4 Brazing 922 33.5 Soldering 931 Case Study Impeller of a Pharmaceutical Company Industrial Shredder/Disposal 937 Chapter 34 Adhesive Bonding, Mechanical Fastening, and Joining of Nonmetals 938 34.1 Adhesive Bonding 938 34.2 Mechanical Fastening 947 34.3 Joining of Plastics 951 34.4 Joining of Ceramics and Glass 953 34.5 Joining of Composites 954 Case Study Golf Club Heads with Insert 956 Chapter 35 Measurement and Inspection 958 35.1 Introduction 958 35.2 Standards of Measurement 959 35.3 Allowance and Tolerance 964 35.4 Inspection Methods for Measurement 971 35.5 Measuring Instruments 973 35.6 Vision Systems for Measurement 982 35.7 Coordinate Measuring Machines 983 35.8 Angle-Measuring Instruments 984 35.9 Gages for Attributes Measuring 986 Case Study Measuring An Angle 993 Chapter 36 Quality Engineering 994 36.1 Introduction 994 36.2 Determining Process Capability 996 36.3 Introduction to Statistical Quality Control 1004 36.4 Sampling Errors 1008 36.5 Gage Capability 1009 36.6 Just in Time/Total Quality Control 1010 36.7 Six Sigma 1021 36.8 Summary 1024 Case Study Boring QC Chart Blunders 1029 Chapter 37 Surface Engineering 1030 37.1 Introduction 1030 37.2 Abrasive Cleaning and Finishing 1040 37.3 Chemical Cleaning 1045 37.4 Coatings 1048 37.5 Vaporized Metal Coatings 1058 37.6 Clad Materials 1058 37.7 Textured Surfaces 1058 37.8 Coil-Coated Sheets 1059 37.9 Edge Finishing and Burrs 1059 Case Study Dana Lynn's Fatigue Lesson 1064 Chapter 38 Micro/Meso/Nano Fabrication Processes 1067 38.1 Introduction 1067 38.2 Additive Processes 1068 38.3 Metrology at the Micro/Meso/Nano Level 1083 Chapter 39 Manufacturing Automation 1086 39.1 Introduction 1086 39.2 The A(4) Level of Automation 1092 39.3 A(5) Evaluation or Adaptive Control 1101 39.4 A(6) Level of Automation and Beyond 1103 39.5 Robotics 1105 39.6 Computer-Integrated Manufacturing Automation 1113 39.7 Computer-Aided Design 1114 39.8 Computer-Aided Manufacturing 1117 39.9 Summary 1118 Chapter 40 NC/CNC Processes and Adaptive Control: A(4) and A(5) Levels of Automation 1122 40.1 Introduction 1122 40.2 Basic Principles of Numerical Control 1122 40.3 Machining Center Features and Trends 1136 40.4 Ultra-High-Speed Machining Centers 1139 40.5 Summary 1140 Chapter 41 Microelectric Manufacturing and Assembly 1144 (web-based chapter) (www.wiley.com/college/DeGarmo) 41.1 Introduction 1144 41.2 How Electronic Products Are Made 1144 41.3 Semiconductors 1145 41.4 How Integrated Circuits Are Made 1146 41.5 How the Silicon Wafer Is Made 1149 41.6 Fabricating Integrated Circuits on Silicon Wafers 1150 41.7 Thin-Film Deposition 1157 41.8 Integrated Circuit Packaging 1163 41.9 Printed Circuit Boards 1170 41.10 Electronic Assembly 1175 Chapter 42 Thread and Gear Manufacturing 1181 (web-based chapter) (www.wiley.com/college/DeGarmo) 42.1 Introduction 1181 42.2 Thread Making 1186 42.3 Internal Thread Cutting-Tapping 1190 42.4 Thread Milling 1193 42.5 Thread Grinding 1195 42.6 Thread Rolling 1195 42.7 Gear Making 1197 42.8 Gear Types 1200 42.9 Gear Manufacturing 1202 42.10 Machining of Gears 1203 42.11 Gear Finishing 1210 42.12 Gear Inspection 1212 Chapter 43 Nondestructive Inspection and Testing 1215 (web-based chapter) (www.wiley.com/college/DeGarmo) 43.1 Destructive versus Nondestructive Testing 1215 43.2 Other Methods of Nondestructive Testing and Inspection 1226 Chapter 44 The Enterprise (Production Systems) 1230 (web-based chapter) (www.wiley.com/college/DeGarmo) 44.1 Introduction 1230 44.2 Axiomatic Design of Systems 1231 44.3 Enterprise System Design Principles 1232 44.4 Functional Areas in the Production System 1235 44.5 Human Resources (Personnel) Department 1240 Index I-2 Selected References for Additional Study S1
