Manufacturing Process and Material Selection

Kalpakjian 2006

1.The Structure of Metals

Behavior and Manufacturing Properties of Part I Crystal Structure of Metals Permanent Deformation Defects in a Single-Crystal Lattice Edge Dislocation Movement Solidification of Molten Metal Plastic Deformation of Idealized Grains Recovery, Recrystallization, and Grain Growth Effects Temperature Ranges for Cold, Warm and Hot Working

2.Mechanical Behavior, Testing, and Manufacturing Properties of Materials

Relative Mechanical Properties of Materials Tensile-test Specimen and Machine Tension Test Stress-strain Curve Mechanical Properties of Materials Tension and Stress Curves Temperature Effects on Stress-strain Curves Strain and Deformation Rate in Manufacturing Hardness-testing Methods and Formulas S-N Curves Endurance Limit vs. Tensile Strength Creep Curve Material Failures Temperature Transition in Metals

3.Physical Properties of Materials

Physical Properties Ratio of Maximum Yield Stress to Density Specific Strength and Stiffness Specific Strength as a Function of Temperature

4. Metal Alloys: Structure and Strengthening by Heat Treatment

Two Phase Systems Cooling of Metals Unit Cells Microstructure of Steel Formed from Eutectoid Composition Microstructure for Cast Irons Martensite Hardness of Tempered Martensite Hardness and Toughness in Steel as a Function of Carbide Shape Effect of Time and Temperature on Yield Stress Hardness of Steel as a Function of Carbon Content

5. Ferrous Metals and Alloys: Production, General Properties, and Applications Casting Carbon and Alloy Steel Applications Tool and Die Materials

6.Nonferrous Metals and Alloys: Production, General Properties, and Applications Cost of Wrought Metals and Plastics vs. Carbon Steel Aluminum Alloy Properties Properties

7.Ceramics, Graphite, and Diamond: Structure, General Properties, and Applications Ceramic Components Ceramic Types and Characteristics Properties of Ceramics

8.Polymers: Structure, General Properties and Applications

Mechanical Properties of Engineering Plastics Structure of Polymer Molecules The Effect of Molecular Weight and Degree of Polymerization on Polymers Polymer Chains Behavior of Polymers Amorphous and Crystalline Regions in a Polymer Glass-Transition and Melting Temperatures of Polymers Types of Plastics Effect of Temperature on Plastic Impact Strength

9.Composite Materials: Structure, General Properties and Applications Methods of Reinforcing Plastics Tensile Strength and Modulus for Fibers in Plastic Properties of Reinforcing Fibers Mechanical Properties of Reinforced Plastics Metal-Matrix Composite Parts

10. Fundamentals of Metal Casting

Solidification of Pure Metals Cast Structures of Solidified Metals Basic Types of Cast Structures

11. Metal-Casting Processes

Summary of Casting Processes Typical Cast Parts Characteristics of Casting Production Steps in Sand-Casting Sand Mold Sequence of Operations in Making a Ceramic Mold Investment Casting Process Vacuum-Casting Hot-Chamber Die-Casting Cold-Chamber Die-Casting Properties and Applications of Die-Casting Alloys Melt-Spinning

12.Metal Casting, Design, Materials, and Economics General Design Rules for Casting Locating and Designing Gates Design Rules for Casting Shrinkage Allowance for Casting in Sand Molds Casting Applications and Characteristics Cost Characteristics of Casting

13.Rolling of Metals
Flat-Rolling and Shape-Rolling Processes Roll Arrangements Bending of Rolls Effects of Hot Rolling Thread-Rolling Processes Machined and Rolled Threads Various Tube-Rolling Processes

14.Forging of Metals
Forged Components Microstructure as a Function of Manufacturing Method Characteristics of Forging Cogging Operation on a Rectangular Bar Impression-Die Forging Forging a Rod, Fullering, and Edging Force in Impression Die Forging The Coining Process Heading Swaging Metals in Decreasing Order of Forgeability Principles of Various Forging Machines Cost-per-piece in Forging

15.Extrusion and Drawing of Metals

Direct-Extrusion Extrusions and Products Made from Extrusions Types of Extrusion Process Variables in Direct Extrusion Extrusion Force Types of Metal Flow in Extrusion with Square Dies Extrusion Temperature Ranges Impact Extrusion Process Variables in Wire Drawing Tube-Drawing Operations Drawing Dies Multistage Wire-drawing Machine

16.Sheet-Metal Forming Processes

Characteristics of Sheet-Metal Forming Processes Shearing with a Punch and Die Shearing Die-Cutting Operations Conventional Versus Fine-Blanking Slitting with Rotary Knives The Shaving Process Shear Angles Compound Die and Progressive Die Characteristics of Metals Used in Sheet-Forming Cupping Test and Bulge-Test Forming Limit Diagram Bending Terminology Minimum Bend Radius Springback in Bending Methods of Reducing or Eliminating Springback Common Die-Bending Operations Bending Operations Flanging Operations Roll-Forming Process Manufacturing of Bellows Deep-Drawing Relationship between Average Normal Anisotropy and the Limiting Drawing Ratio Bending and Embossing of Sheet Metal Hydroform Process Tube-Hydroforming Explosive Forming Cymbal Manufacture Manufacturing Honeycomb Structures Cost of Conventional Spinning Versus Cost of Deep Drawing

17.Processing of Metal Powders

Parts Made by Powder-Metallurgy Steps in Making Powder-Metallurgy Parts Particle Shapes in Metal Powders Mechanical Comminution to Obtain Fine Particles Compaction Density as a Function of Pressure and the Effects of Density on Other Properties Compacting Pressures for Various Powders Sintering Time and Temperature for Metals Mechanical Properties of P/M Materials Design Considerations for P/M

18.Processing of Ceramics, Glass, and Superconductors

Characteristics of Ceramics Processing Steps in Making Ceramic Parts Doctor-Blade Process Extruding and Jiggering Shrinkage of Wet Clay Drawing Process and Rolling Process Glass Tubing Manufacturing Steps in Manufacturing Glass Bottles Manufacturing Glass by Pressing into Mold Centrifugal Casting of Glass Powder-In-Tube Process

19.Forming and Shaping Plastics and Composite Materials

Characteristics of Forming and Shaping Processes for Plastics and Composite Materials Forming and Shaping Processes for Plastics, Elastomers, and Composite Materials Extruder Schematic Extrusion Die Geometries Extrusion of Tubes Melt-Spinning Process Injection Molding Blow-Molding Thermoforming Process Compression Molding Transfer Molding Vacuum-Bag Forming and Pressure-Bag Forming Open-Mold Processing Filament-Winding Production Characteristics of Molding Methods

20.Rapid-Prototyping Operations
Characteristics of Additive Rapid-Prototyping Technologies Mechanical Properties of Selected Materials for Rapid Prototyping Fused-Deposition-Modeling Stereolithography Selective-Laser-Sintering Three-Dimensional-Printing Laminated-Object-Manufacturing Investment Casting Using Rapid-Prototyped Wax Parts