Manufacturing

Processes for
Engineering
Materials
F
l T I 1
I r i n
E
n I 1 N
L/ 1 1 1 XJ I
In SI Uni ts
Serope Kalpakjian
Illinois Institute of Technology, Chicago, Illinois
Steven R. Schmid
University of Notre Dame, Notre Dame, Indiana
SI conversion by Chi-Wah Kok
Hong Kong University of Science and Technology
PEARSON
Prentice
Hall
Singapore London New York Toront o Sydney Tokyo Madr i d
Mexi co City Muni ch Paris Capet own Hong Kong Mont real
CONTENTS
Preface xvii
About the Authors ... xxi
Introduction 1
1.1 What Is Manufacturing? 1
1.2 Product Design and Concurrent Engineering 7
1.3 Design for Manufacture, Assembly, Disassembly, and Service
1.4 Environmentally Conscious Design, Sustainable
Manufacturing, and Product Life Cycle 12
1.5 Selecting Materials 13
1.6 Selecting Manufacturing Processes 15
1.7 Computer-Integrated Manufacturing 19
1.8 Lean Production and Agile Manufacturing 22
1.9 Quality Assurance and Total Quality Management 22
1.10 Manufacturing Costs and Global Competitiveness 24
1.11 General Trends in Manufacturing 25
Summary 26
References 26
Bibliography 28
Fundamentals of the Mechanical
Behavior of Materials 29
2.1 Introduction 29
2.2 Tension 30
2.3 Compression 45
2.4 Torsion 48
2.5 Bending 50
2.6 Hardness 51
2.7 Fatigue 56
2.8 Creep 58
2.9 Impact 59
2.10 Residual Stresses 59
2.11 Triaxial Stresses and Yield Criteria 62
2.12 Work of Deformation 70
Summary 74
Summary of Equations 76
Bibliography 77
Questions 77
Problems 79
2
viii CONTENTS
J Structure and Manufacturing
Properties of Metals 83
3.1 Introduction 83
3.2 The Crystal Structure of Metals 84
3.3 Deformation and Strength of Single Crystals 85
3.4 Grains and Grain Boundaries 91
3.5 Plastic Deformation of Polycrystalline Metals 94
3.6 Recovery, Recrystallization, and Grain Growth 95
3.7 Cold, Warm, and Hot Working 98
3.8 Failure and Fracture 98
3.9 Physical Properties 105
3.10 General Properties and Applications of Ferrous Alloys 110
3.11 General Properties and Applications of Nonferrous
Metals and Alloys 115
Summary 126
Summary of Equations 127
Bibliography 127
Questions 128
Problems 129
Surfaces, Tribology, Dimensional
Characteristics, Inspection, and
Product Quality Assurance 131
4.1 Introduction 131
4.2 Surface Structure and Properties 132
4.3 Surface Texture and Roughness 134
4.4 Tribology: Friction, Wear, and Lubrication 138
4.5 Surface Treatments, Coatings, and Cleaning 154
4.6 Engineering Metrology and Instrumentation 164
4.7 Dimensional Tolerances 170
4.8 Testing and Inspection 172
4.9 Quality Assurance 175
Summary 183
Summary of Equations 183
Bibliography 184
Questions 185
Problems 186
Metal-Casting Processes and
Equipment; Heat Treatment 188
5.1 Introduction 188
5.2 Solidification of Metals 189
5.3 Cast Structures 195
CONTENTS ix
5.4 Fluid Flow and Heat Transfer 199
5.5 Melting Practice and Furnaces 207
5.6 Casting Alloys 208
5.7 Ingot Casting and Continuous Casting 214
5.8 Expendable-Mold, Permanent-Pattern Casting Processes 217
5.9 Expendable-Mold, Expendable-Pattern Casting Processes 223
5.10 Permanent-Mold Casting Processes 227
5.11 Heat Treatment 236
5.12 Design Considerations 245
5.13 Economics of Casting 254
Case Study: Lost-Foam Casting of Engine Blocks 255
Summary 256
Summary of Equations 257
Bibliography 257
Questions 258
Problems 260
Design 262
Bulk Deformation Processes 265
6.1 Introduction 265
6.2 Forging 266
6.3 Rolling 288
6.4 Extrusion 307
6.5 Rod, Wire, and Tube Drawing 320
6.6 Swaging 329
6.7 Die Manufacturing Methods 331
6.8 Die Failures 332
6.9 Economics of Bulk Forming 333
Case Study: Suspension Components for the Lotus Elise
Automobile 334
Summary 336
Summary of Equations 336
Bibliography 338
Questions 338
Problems 340
Design 344
Sheet-Metal Forming Processes 346
7.1 Introduction 346
7.2 Sheet-Metal Characteristics 347
7.3 Shearing 351
7.4 Bending of Sheet and Plate 360
7.5 Miscellaneous Forming Processes 372
7.6 Deep Drawing 387
7.7 Formability of Sheet Metals and Modeling 397
7.8 Equipment for Sheet-Metal Forming 403
7.9 Design Considerations 404
7.10 Economics of Sheet-Metal Forming 406
Case Study: Cymbal Manufacture 407
Summary 409
Summary of Equations 410
Bibliography 411
Questions 411
Problems 413
Design 415
Material-Removal Processes: Cutting 416
8.1 Introduction 416
8.2 Mechanics of Chip Formation 418
8.3 Tool Wear and Failure 440
8.4 Surface Finish and Surface Integrity 447
8.5 Machinability 450
8.6 Cutting-Tool Materials 453
8.7 Cutting Fluids 464
8.8 High-Speed Machining 466
8.9 Machining Processes and Machine Tools for Producing
Round Shapes 467
8.10 Machining Processes and Machine Tools for Producing
Various Shapes 482
8.11 Machining and Turning Centers 495
8.12 Vibration and Chatter 501
8.13 Machine-Tool Structures 503
8.14 Design Considerations 504
8.15 Economics of Machining 507
Case Study: Ping Golf Putters 510
Summary 512
Summary of Equations 513
Bibliography 514
Questions 515
Problems 518
Design 521
Material-Removal Processes: Abrasive,
Chemical, Electrical, and High-Energy
Beams 523
9.1 Introduction 523
9.2 Abrasives 524
9.3 Bonded Abrasives 526
9.4 Mechanics of Grinding 530
9.5 Grinding Wheel Wear 536
9.6 Grinding Operations and Machines 540
CONTENTS XI
9.7 Finishing Operations 547
9.8 Deburring 551
9.9 Ultrasonic Machining 552
9.10 Chemical Machining 554
9.11 Electrochemical Machining 558
9.12 Electrochemical Grinding 560
9.13 Electrical-Discharge Machining 561
9.14 High-Energy-Beam Machining 566
9.15 Water-Jet, Abrasive Water-Jet, and Abrasive-Jet
Machining 568
9.16 Design Considerations 570
9.17 Process Economics 573
Case Study: Manufacture of Stents 574
Summary 576
Summary of Equations 577
Bibliography 578
Questions 579
Problems 580
Design 582
Properties and Processing of Polymers
and Reinforced Plastics; Rapid
Prototyping and Rapid Tooling 584
10.1 Introduction 584
10.2 The Structure of Polymers 587
10.3 Thermoplastics: Behavior and Properties 594
10.4 Thermosets: Behavior and Properties 601
10.5 Thermoplastics: General Characteristics
and Applications 601
10.6 Thermosets: General Characteristics
and Applications 604
10.7 High-Temperature Polymers, Electrically Conducting
Polymers, and Biodegradable Plastics 605
10.8 Elastomers (Rubbers): General Characteristics
and Applications 607
10.9 Reinforced Plastics 608
10.10 Processing of Plastics 619
10.11 Processing of Polymer-Matrix-Reinforced Plastics 637
10.12 Rapid Prototyping and Rapid Tooling 643
10.13 Design Considerations 656
10.14 Economics of Processing Plastics 657
Case Study: Invisalign Orthodontic Aligners 658
Summary 660
Summary of Equations 661
Bibliography 662
Questions 663
Problems 666
Design 667
XII CONTENTS
I I Properties and Processing of Metal
Powders, Ceramics, Glasses,
and Superconductors 669
11.1 Introduction 669
11.2 Powder Metallurgy 670
11.3 Compaction of Metal Powders 676
11.4 Sintering 685
11.5 Secondary and Finishing Operations 691
11.6 Design Considerations for Powder Metallurgy 692
11.7 Economics of Powder Metallurgy 695
11.8 Ceramics: Structure, Properties, and Applications 697
11.9 Shaping Ceramics 706
11.10 Glasses: Structure, Properties, and Applications 712
11.11 Forming and Shaping Glass 714
11.12 Design Considerations for Ceramic and Glass Products 71 i
11.13 Graphite and Diamond 719
11.14 Processing Metal-Matrix and Ceramic-Matrix
Composites 720
11.15 Processing Superconductors 723
Case Study: Hot Isostatic Pressing of Valve Lifter 724
Summary 725
Summary of Equations 726
Bibliography 727
Questions 727
Problems 729
Design 730
IZ Joining and Fastening Processes 732
12.1 Introduction 732
12.2 Oxyfuel Gas Welding 734
12.3 Arc Welding Processes: Consumable Electrode 736
12.4 Arc Welding Processes: Nonconsumable Electrode 744
12.5 High-Energy-Beam Welding 746
12.6 The Fusion Welded Joint 749
12.7 Cold Welding 760
12.8 Ultrasonic Welding 761
12.9 Friction Welding 762
12.10 Resistance Welding 764
12.11 Explosion Welding 770
12.12 Diffusion Bonding 771
12.13 Brazing and Soldering 772
12.14 Adhesive Bonding 780
12.15 Mechanical Fastening 784
12.16 Joining Nonmetallic Materials 788
12.17 Design Considerations in Joining 790
12.18 Economic Considerations 794
CONTENTS XIII
Case Study: Friction Welding of Monosteel Pistons 795
Summary 796
Summary of Equations 797
Bibliography 797
Questions 798
Problems 801
Design 802
IJ Fabrication of Microelectronic,
Micromechanical, and
Microelectromechanical Devices;
Nanomanufacturing 803
13.1 Introduction 803
13.2 Clean Rooms 807
13.3 Semiconductors and Silicon 808
13.4 Crystal Growing and Wafer Preparation 809
13.5 Films and Film Deposition 812
13.6 Oxidation 813
13.7 Lithography 815
13.8 Etching 822
13.9 Diffusion and Ion Implantation 832
13.10 Metallization and Testing 833
13.11 Wire Bonding and Packaging 835
13.12 Yield and Reliability of Chips 839
13.13 Printed Circuit Boards 839
13.14 Micromachining of MEMS Devices 841
13.15 LIGA and Related Microfabrication Processes 851
13.16 Solid Freeform Fabrication of Devices 857
13.17 Mesoscale Manufacturing 858
13.18 Nanoscale Manufacturing 859
Case Study: Digital Micromirror Device 860
Summary 863
Bibliography 864
Questions 865
Problems 866
Design 867
14 Automation of Manufacturing
Processes and Operations 869
14.1 Introduction 869
14.2 Automation 870
14.3 Numerical Control 877
14.4 Programming for Numerical Control 883
14.5 Adaptive Control 884
XIV CONTENTS
14.6 Material Handling and Movement 887
14.7 Industrial Robots 890
14.8 Sensor Technology 895
14.9 Flexible Fixturmg 899
14.10 Assembly, Disassembly, and Service 901
14.11 Design Considerations 904
14.12 Economic Considerations 907
Case Study: Robotic Deburring of Plastic Toboggans 908
Summary 909
Bibliography 910
Questions 910
Problems 912
Design 912
I J Computer-Integrated Manufacturing
Systems 914
15.1 Introduction 914
15.2 Manufacturing Systems 915
15.3 Computer-Integrated Manufacturing 916
15.4 Computer-Aided Design and Engineering 918
15.5 Computer-Aided Manufacturing 923
15.6 Computer-Aided Process Planning 924
15.7 Computer Simulation of Manufacturing Processes
and Systems 927
15.8 Group Technology 929
15.9 Cellular Manufacturing 935
15.10 Flexible Manufacturing Systems 937
15.11 Holonic Manufacturing 940
15.12 Just-in-Time Production 941
15.13 Lean Manufacturing 943
15.14 Communications Networks in Manufacturing 943
15.15 Artificial Intelligence 946
Summary 949
Bibliography 950
Questions 951
Problems 952
Design 952
CONTENTS XV
I Product Design and Manufacturing
in a Global Competitive
Environment 954
16.1 Introduction 954
16.2 Product Design and Robust Design 955
16.3 Product Quality and Quality Management 960
16.4 Life-Cycle Engineering and Sustainable Manufacturing 966
16.5 Selection of Materials for Products 968
16.6 Substitution of Materials in Products 972
16.7 Capabilities of Manufacturing Processes 974
16.8 Selection of Manufacturing Processes 978
16.9 Manufacturing Costs and Cost Reduction 980
Summary 983
Summary of Equations 984
Bibliography 984
Questions 985
Problems 986
Design 986
Answers to Selected Problems 991
Index 993