Manufacturing Engineering and Technology, 9th edition

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 Metals
• 1.1: Introduction
• 1.2: Types of Atomic Bonds
• 1.3: The Crystal Structure of Metals
• 1.4: Deformation and Strength of Single Crystals
• 1.5: Grains and Grain Boundaries
• 1.6: Plastic Deformation of Polycrystalline Metals
• 1.7: Recovery, Recrystallization, and Grain Growth
• 1.8: Cold, Warm, and Hot Working
• 2: Mechanical Behavior, Testing, and Manufacturing Properties of Materials
• 2.1: Introduction
• 2.2: Tension
• 2.3: Compression
• 2.4: Torsion
• 2.5: Bending (Flexure)
• 2.6: Hardness
• 2.7: Fatigue
• 2.8: Creep
• 2.9: Impact
• 2.10: Failure and Fracture of Materials
• 2.11: Residual Stresses
• 2.12: Work, Heat, and Temperature
• 3: Physical Properties of Materials
• 3.1: Introduction
• 3.2: Density
• 3.3: Melting Point
• 3.4: Specific Heat
• 3.5: Thermal Conductivity
• 3.6: Thermal Expansion
• 3.7: Electrical, Magnetic, and Optical Properties
• 3.8 : Corrosion Resistance
• 4: Metal Alloys: Their Structure and Strengthening by Heat Treatment
• 4.1: Introduction
• 4.2: Structure of Alloys
• 4.3: Phase Diagrams
• 4.4: The Iron–Carbon System
• 4.5: The Iron–Iron-carbide Phase Diagram and the Development of Microstructures in Steels
• 4.6: Cast Irons
• 4.7: Heat Treatment of Ferrous Alloys
• 4.8: Hardenability of Ferrous Alloys
• 4.9: Heat Treatment of Nonferrous Alloys and Stainless Steels
• 4.10: Case Hardening
• 4.11: Annealing
• 4.12: Heat Treating Furnaces and Equipment
• 4.13: Design Considerations for Heat Treating
• 5: Ferrous Metals and Alloys: Production, General Properties, and Applications
• 5.1: Introduction
• 5.2: Production of Iron and Steel
• 5.3: Casting of Ingots
• 5.4: Continuous Casting
• 5.5: Carbon and Alloy Steels
• 5.6: Stainless Steels
• 5.7: Tool and Die Steels
• 6: Nonferrous Metals and Alloys: Production, General Properties, and Applications
• 6.1: Introduction
• 6.2: Aluminum and Aluminum Alloys
• 6.3: Magnesium and Magnesium Alloys
• 6.4: Copper and Copper Alloys
• 6.5: Nickel and Nickel Alloys
• 6.6: Superalloys
• 6.7: Titanium and Titanium Alloys
• 6.8: Refractory Metals and Alloys
• 6.9: Beryllium
• 6.10: Zirconium
• 6.11: Lithium
• 6.12: Low-melting Alloys
• 6.13: Precious Metals
• 6.14: Shape-memory Alloys (Smart Materials)
• 6.15: Amorphous Alloys (Metallic Glasses)
• 6.16: Metal Foams and Metamaterials
• 6.17: Rare Earth Metals
• 7: Polymers: Structure, General Properties, and Applications
• 7.1: Introduction
• 7.2: The Structure of Polymers
• 7.3: Thermoplastics
• 7.4: Thermosetting Plastics
• 7.5: Additives in Plastics
• 7.6: General Properties and Applications of Thermoplastics
• 7.7: General Properties and Applications of Thermosetting Plastics
• 7.8: Biodegradable Plastics
• 7.9: Elastomers (Rubbers)
• 7.10: Gels
• 8: Ceramics, Glass, Graphite, Diamond, and Nanomaterials: Structure, General Properties, and Applications
• 8.1: Introduction
• 8.2: The Structure of Ceramics
• 8.3: General Properties and Applications of Ceramics
• 8.4: Glasses
• 8.5: Glass Ceramics
• 8.6: Graphite
• 8.7: Diamond
• 8.8: Nanomaterials
• 9: Composite Materials: Structure, General Properties, and Applications
• 9.1: Introduction
• 9.2: The Structure of Reinforced Plastics
• 9.3: Properties of Reinforced Plastics
• 9.4: Applications of Reinforced Plastics
• 9.5: Metal-matrix Composites
• 9.6: Ceramic-matrix Composites
• 9.7: Other Composites

II: Metal-casting Processes and Equipment

• 10: Fundamentals of Metal Casting
• 10.1: Introduction
• 10.2: Solidification of Metals
• 10.3: Fluid Flow
• 10.4: Fluidity of Molten Metal
• 10.5: Heat Transfer
• 10.6: Defects
• 11: Metal-casting Processes and Equipment
• 11.1: Introduction
• 11.2: Expendable-mold, Permanent-pattern Casting Processes
• 11.3: Expendable-mold, Expendable-pattern Casting Processes
• 11.4: Permanent-mold Casting Processes
• 11.5: Casting Techniques for Single-crystal Components
• 11.6: Rapid Solidification
• 11.7: Inspection of Castings
• 11.8: Melting Practice and Furnaces
• 11.9: Foundries and Foundry Automation
• 12: Metal Casting: Design, Materials, and Economics
• 12.1: Introduction
• 12.2: Design Considerations in Casting
• 12.3: Casting Alloys
• 12.4: Economics of Casting

III: Forming and Shaping Processes and Equipment

• 13: Metal-rolling Processes and Equipment
• 13.1: Introduction
• 13.2: The Flat-rolling Process
• 13.3: Flat-rolling Practice
• 13.4: Rolling Mills
• 13.5: Various Rolling Processes and Mills
• 14: Metal-forging Processes and Equipment
• 14.1: Introduction
• 14.2: Open-die Forging
• 14.3: Impression-die and Closed-die Forging
• 14.4: Various Forging Operations
• 14.5: Forgeability of Metals; Forging Defects
• 14.6: Die Design, Die Materials, and Lubrication
• 14.7: Die-manufacturing Methods and Die Failures
• 14.8: Forging Machines
• 14.9: Economics of Forging
• 15: Metal Extrusion and Drawing Processes and Equipment
• 15.1: Introduction
• 15.2: The Extrusion Process
• 15.3: Hot Extrusion
• 15.4: Cold Extrusion
• 15.5: Extrusion Defects
• 15.6: Design Considerations
• 15.7: Extrusion Equipment
• 15.8: The Drawing Process
• 15.9: Drawing Practice
• 15.10: Drawing Defects and Residual Stresses
• 15.11: Drawing Equipment
• 16 : Sheet-Metal Forming Processes and Equipment
• 16.1: Introduction
• 16.2: Shearing
• 16.3: Sheet-metal Characteristics and Formability
• 16.4: Formability Tests for Sheet Metals
• 16.5: Bending Sheets, Plates, and Tubes
• 16.6: Miscellaneous Bending and Related Forming Operations
• 16.7: Deep Drawing
• 16.8: Rubber Forming and Hydroforming
• 16.9: Spinning
• 16.10: Superplastic Forming
• 16.11: Hot Stamping
• 16.12: Specialized Forming Processes
• 16.13: Manufacturing of Metal Honeycomb Structures
• 16.14: Design Considerations in Sheet-metal Forming
• 16.15: Equipment for Sheet-metal Forming
• 16.16: Economics of Sheet-forming Operations
• 17: Powder-Metal Processes and Equipment
• 17.1: Introduction
• 17.2: Production of Metal Powders
• 17.3: Compaction of Metal Powders
• 17.4: Sintering
• 17.5: Secondary and Finishing Operations
• 17.6: Design Considerations
• 17.7: Economics of Powder Metallurgy
• 18: Ceramics, Glasses, and Superconductors: Processing and Equipment
• 18.1: Introduction
• 18.2: Shaping Ceramics
• 18.3: Forming and Shaping of Glass
• 18.4: Techniques for Strengthening and Annealing Glass
• 18.5: Design Considerations for Ceramics and Glasses
• 18.6: Processing of Superconductors
• 19: Plastics and Composite Materials: Forming and Shaping
• 19.1: Introduction
• 19.2: Extrusion
• 19.3: Injection Molding
• 19.4: Blow Molding
• 19.5: Rotational Molding
• 19.6: Thermoforming
• 19.7: Compression Molding
• 19.8: Transfer Molding
• 19.9: Casting
• 19.10: Foam Molding
• 19.11: Cold Forming and Solid-phase Forming
• 19.12: Processing Elastomers
• 19.13: Processing Polymer-Matrix Composites
• 19.14: Processing Metal-Matrix and Ceramic-Matrix Composites
• 19.15: Design Considerations
• 19.16: Economics of Processing Plastics and Composite Materials
• 20: Additive Manufacturing
• 20.1: Introduction
• 20.2: Additive Manufacturing Methodology
• 20.3: Material Extrusion
• 20.4: Vat Polymerization
• 20.5: Material Jetting
• 20.6: Binder Jetting
• 20.7: Powder Bed Fusion
• 20.8: Sheet Lamination
• 20.9: Directed Energy Deposition
• 20.10: Miscellaneous Processes
• 20.11: Direct Manufacturing and Rapid Tooling
• 20.12: Design for Additive Manufacturing
• 20.13: Additive Manufacturing Economics

IV: Machining Processes and Machine Tools

• 21: Fundamentals of Machining
• 21.1: Introduction
• 21.2: Mechanics of Cutting
• 21.3: Cutting Forces and Power
• 21.4: Temperatures in Cutting
• 21.5: Tool Life: Wear and Failure
• 21.6: Surface Finis
• 21.7: Machinability
• 22: Cutting-Tool Materials and Cutting Fluids
• 22.1: Introduction
• 22.2: High-speed Steels
• 22.3: Cast-cobalt Alloys
• 22.4: Carbides
• 22.5: Coated Tools
• 22.6: Alumina-based Ceramics
• 22.7: Cubic Boron Nitride
• 22.8: Silicon-Nitride-based Ceramics
• 22.9: Diamond
• 22.10: Whisker-reinforced Materials and Nanomaterials
• 22.11: Tool Costs and Reconditioning of Tools
• 22.12: Cutting Fluids
• 23: Machining Processes: Turning and Hole Making
• 23.1: Introduction
• 23.2: The Turning Process
• 23.3: Lathes and Lathe Operations
• 23.4: Boring and Boring Machines
• 23.5: Drilling, Drills, and Drilling Machines
• 23.6: Reaming and Reamers
• 23.7: Tapping and Taps
• 24: Machining Processes: Milling, Broaching, Sawing, Filing, and Gear Manufacturing
• 24.1: Introduction
• 24.2: Milling and Milling Machines
• 24.3: Planing and Shaping
• 24.4: Broaching and Broaching Machines
• 24.5: Sawing
• 24.6: Filing
• 24.7: Gear Manufacturing by Machining
• 25: Machining Centers, Machine-tool Structures, and Machining
• 25.1: Introduction
• 25.2: Machining Centers
• 25.3: Machine-tool Structures
• 25.4: Vibration and Chatter in Machining Operations
• 25.5: High-speed Machining
• 25.6: Hard Machining
• 25.7: Ultraprecision Machining
• 25.8: Machining Economics
• 26: Abrasive Machining and Finishing Operations
• 26.1: Introduction
• 26.2: Abrasives and Bonded Abrasives
• 26.3: The Grinding Process
• 26.4: Grinding Operations and Machines
• 26.5: Design Considerations for Grinding
• 26.6: Ultrasonic Machining
• 26.7: Finishing Operations
• 26.8: Deburring Operations
• 26.9: Economics of Abrasive Machining and Finishing Operations
• 27: Advanced Machining Processes
• 27.1: Introduction
• 27.2: Chemical Machining
• 27.3: Electrochemical Machining
• 27.4: Electrochemical Grinding
• 27.5: Electrical-Discharge Machining
• 27.6: Laser-beam Machining
• 27.7: Electron-beam Machining
• 27.8: Water-jet Machining
• 27.9: Abrasive-jet Machining
• 27.10: Hybrid Machining Systems

V: Micromanufacturing and Fabrication of Microelectronic Devices

• 28: Fabrication of Microelectronic Devices
• 28.1: Introduction
• 28.2: Clean Rooms
• 28.3: Semiconductors and Silicon
• 28.4: Crystal Growing and Wafer Preparation
• 28.5: Film Deposition
• 28.6: Oxidation
• 28.7: Lithography
• 28.8: Etching
• 28.9: Diffusion and Ion Implantation
• 28.10: Metallization and Testing
• 28.11: Wire Bonding and Packaging
• 28.12: Yield and Reliability
• 28.13: Printed Circuit Boards
• 28.14: Roll-to-Roll Printing of Flexible Electronics
• 28.15: Flexible Hybrid Electronics
• 29: Fabrication of Microelectromechanical Devices and Systems and Nanoscale Manufacturing
• 29.1: Introduction
• 29.2: Micromachining of MEMS Devices
• 29.3: Electroforming-based Processes
• 29.4: Solid Free-form Fabrication of Devices
• 29.5: Mesoscale Manufacturing
• 29.6: Nanoscale Manufacturing

VI: Joining Processes and Equipment

• 30: Fusion Welding Processes
• 30.1: Introduction
• 30.2: Oxyfuel–Gas Welding
• 30.3: Arc-welding Processes: Nonconsumable Electrode
• 30.4: Arc-welding Processes: Consumable Electrode
• 30.5: Electrodes for Arc Welding
• 30.6: Electron-beam Welding
• 30.7: Laser-beam Welding
• 30.8: Cutting
• 30.9: The Weld Joint, Quality and Testing
• 30.10: Joint Design and Process Selection
• 31: Solid-state Welding Processes
• 31.1: Introduction
• 31.2: Cold Welding and Roll Bonding
• 31.3: Ultrasonic Welding
• 31.4: Friction Welding
• 31.5: Resistance Welding
• 31.6: Explosion Welding
• 31.7: Diffusion Bonding
• 31.8: Economics of Welding Operations
• 32: Brazing, Soldering, Adhesive-bonding, and Mechanical Fastening Processes
• 32.1: Introduction
• 32.2: Brazing
• 32.3: Soldering
• 32.4: Adhesive Bonding
• 32.5: Mechanical Fastening
• 32.6: Joining Plastics, Ceramics, and Glasses
• 32.7: Economics of Joining Operations

VII: Surface Technology

• 33: Surface Roughness and Measurement; Friction, Wear, and Lubrication
• 33.1: Introduction
• 33.2: Surface Structure and Integrity
• 33.3: Surface Texture and Roughness
• 33.4: Friction
• 33.5: Wear
• 33.6: Lubrication
• 33.7: Metalworking Fluids and Their Selection
• 34: Surface Treatments, Coatings, and Cleaning
• 34.1: Introduction
• 34.2: Mechanical Surface Treatments
• 34.3: Mechanical Plating and Cladding
• 34.4: Case Hardening and Hard Facing
• 34.5: Thermal Spraying
• 34.6: Vapor Deposition
• 34.7: Ion Implantation and Diffusion Coating
• 34.8: Laser Treatments
• 34.9: Electroplating, Electroless Plating, and Electroforming
• 34.10: Conversion Coatings
• 34.11: Hot Dipping
• 34.12: Porcelain Enameling; Ceramic and Organic Coatings
• 34.13: Diamond Coating and Diamondlike Carbon
• 34.14: Surface Texturing
• 34.15: Painting
• 34.16: Cleaning of Surfaces

VIII: Engineering Metrology, Instrumentation, and Quality Assurance

• 35: Engineering Metrology and Instrumentation
• 35.1: Introduction
• 35.2: Measurement Standards
• 35.3: Geometric Features of Parts: Analog and Digital Measurements
• 35.4: Traditional Measuring Methods and Instruments
• 35.5: Modern Measuring Instruments and Machines
• 35.6: Automated Measurement
• 35.7: General Characteristics and Selection of Measuring Instruments
• 35.8: Geometric Dimensioning and Tolerancing
• 36: Quality Assurance, Testing, and Inspection
• 36.1: Introduction
• 36.2: Product Quality
• 36.3: Quality Assurance
• 36.4: Total Quality Management
• 36.5: Taguchi Methods
• 36.6: The ISO and QS Standards
• 36.7: Statistical Methods of Quality Control
• 36.8: Statistical Process Control
• 36.9: Reliability of Products and Processes
• 36.10: Nondestructive Testing
• 36.11: Destructive Testing
• 36.12: Automated Inspection

IX: Manufacturing in a Competitive Environment

• 37: Automation of Manufacturing Processes and Operations
• 37.1: Introduction
• 37.2: Automation
• 37.3: Numerical Control
• 37.4: Adaptive Control
• 37.5: Material Handling and Movement
• 37.6: Industrial Robots
• 37.7: Sensor Technology
• 37.8: Flexible Fixturing
• 37.9: Assembly Systems
• 37.10: Design Considerations for Fixturing, Assembly, Disassembly, and Servicing
• 37.11: Economic Considerations
• 38: Computer-aided Manufacturing
• 38.1: Introduction
• 38.2: Manufacturing Systems
• 38.3: Computer-integrated Manufacturing
• 38.4: Computer-aided Design and Engineering
• 38.5: Computer-aided Manufacturing
• 38.6: Computer-aided Process Planning
• 38.7: Computer Simulation of Manufacturing Processes and Systems
• 38.8: Group Technology
• 39: Computer-integrated Manufacturing Systems
• 39.1: Introduction
• 39.2: Cellular Manufacturing
• 39.3: Flexible Manufacturing Systems
• 39.4: Mass Customization
• 39.5: Holonic Manufacturing
• 39.6: Just-in-time Production
• 39.7: Lean Manufacturing
• 39.8: Communications Networks in Manufacturing
• 39.9: Artificial Intelligence and Machine Learning
• 39.10: Economic Considerations
• 40: Product Design and Manufacturing in a Competitive Environment
• 40.1: Introduction
• 40.2: Product Design
• 40.3: Product Quality
• 40.4: Decarbonization and Sustainable Manufacturing
• 40.5: Energy Consumption in Manufacturing
• 40.6: Material Selection for Products
• 40.7: Material Substitution
• 40.8: Manufacturing Process Capabilities
• 40.9: Process Selection
• 40.10: Manufacturing Costs and Cost Reduction

Index