Materials and processes in manufacturing:
Saved in:
| Main Authors: | , , |
|---|---|
| Format: | Book |
| Language: | English |
| Published: |
Upper Saddle River, NJ
Prentice Hall
1997
|
| Edition: | 8. ed. |
| Subjects: | |
| Online Access: | Inhaltsverzeichnis |
| Physical Description: | XI, 1259 S. Ill., graph. Darst. |
| ISBN: | 0023286210 |
Staff View
MARC
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| 245 | 1 | 0 | |a Materials and processes in manufacturing |c E. Paul DeGarmo ; J. T. Black ; Ronald A. Kohser |
| 250 | |a 8. ed. | ||
| 264 | 1 | |a Upper Saddle River, NJ |b Prentice Hall |c 1997 | |
| 300 | |a XI, 1259 S. |b Ill., graph. Darst. | ||
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Record in the Search Index
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|---|---|
| adam_text | CONTENTS Preface ix
Chapter 1 Introduction 1
1.1 Introduction 1
1.2 Manufacturing and Production Systems 5
1.3 Language of Manufacturing or Process
Technology 14
1.4 Product Life Cycle 17
1.5 Basic Manufacturing Processes 18
1.6 Yardstick for Automation 24
1.7 Planning for Manufacturing 28
1.8 New Manufacturing System 30
Case Study: Famous Folks in Manufacturing 33
Parti Materials 34
Chapter 2 Properties
of Materials 36
2.1 Introduction 36
2.2 Static Properties 38
2.3 Dynamic Properties 53
2.4 Physical Properties 64
Case Study: Separating Mixed Materials 67
Chapter 3 Nature of Metals
and Alloys 68
3.1 Structure Property Relationship 68
3.2 Atomic Structure 69
3.3 Atomic Bonds 70
3.4 Secondary Bonds 72
3.5 Interatomic Distances and Size of Atoms 72
3.6 Atom Arrangements in Materials 73
3.7 Crystal Structures of Metals 73
3.8 Development of a Grain Structure 76
3.9 Elastic Deformation of a Single Crystal 77
3.10 Plastic Deformation of a Single Crystal 78
3.11 Dislocation Theory of Slippage 80
3.12 Strain Hardening or Work Hardening 81
3.13 Plastic Deformation in Polycrystalline Metals 82
3.14 Grain Deformation and Ani sotropic
Properties 83
3.15 Fracture of Metals 83
3.16 Cold Working, Recrystallization,
and Hot Working 84
3.17 Grain Growth 86
3.18 Alloys 86
3.19 Alloy Types 86
3.20 Atomic Structure and Electrical Properties 86
Case Study: Window Frame Materials and Design 89
Chapter 4 Equilibrium Diagrams
and the Iron Carbon System 90
4.1 Introduction 90
4.2 Phases 90
4.3 Equilibrium Phase Diagrams 91
4.4 Iron Carbon Equilibrium Diagram 99
4.5 Steels and the Simplified Iron Carbon Diagram 100
4.6 Cast Irons 102
Case Study: The Blacksmith Anvils 109
Chapter 5 Heat Treatment 110
5.1 Introduction 110
5.2 Processing Heat Treatments 111
5.3 Heat Treatments Used to Increase Strength 114
5.4 Strengthening Heat Treatments for Nonferrous
Metals 115
5.5 Strengthening Heat Treatments for Steel 118
5.6 Surface Hardening of Steel 132
5.7 Furnaces 136
5.8 Heat Treatment and Energy 138
Case Study: A Flying Chip from a Sledgehammer 140
Chapter 6 Ferrous Metals
and Alloys 141
6.1 Introduction to History Dependent Materials 141
6.2 Iron 142
6.3 Steel 142
6.4 Stainless Steels 158
6.5 Tool Steels 161
6.6 Alloy Cast Steels and Irons 163
Case Study: Interior Tub of a Top Loading
Washing Machine 166
III
iv Contents
Chapter 7 Nonferrous Metals
and Alloys 167
7.1 Introduction 167
7.2 Copper and Copper Alloys 168
7.3 Aluminum and Aluminum Alloys 174
7.4 Magnesium and Magnesium Alloys 182
7.5 Zinc Based Alloys 183
7.6 Titanium and Titanium Alloys 185
7.7 Nickel Based Alloys 186
7.8 Superalloys and Other Nonferrous Metals
for High Temperature Service 187
7.9 Lead, Tin, and Their Alloys 187
7.10 Some Less Known Metals and Alloys 190
7.11 Graphite 190
Case Study: Nonsparking Wrench 192
Chapter 8 Nonmetallic
Materials: Plastics, Elastomers,
Ceramics, and Composites 193
8.1 Introduction 193
8.2 Plastics 194
8.3 Elastomers 205
8.4 Ceramics 207
8.5 Composite Materials 214
Case Study: Two Wheel Dolly Handles 222
Chapter 9 Material
Selection 227
9.1 Introduction 227
9.2 Material Selection and Manufacturing 230
9.3 Design Process 231
9.4 Procedure for Material Selection 232
9.5 Additional Factors to Consider 235
9.6 Consideration of the Manufacturing Process 236
9.7 Ultimate Objective 237
9.8 Materials Substitution 237
9.9 Effect of Product Liability
on Materials Selection 238
9.10 Aids to Material Selection 239
Case Study: Material Selection 242
Part 2 Measurement
and Quality Assurance 243
Chapter 10 Measurement
and Inspection 244
10.1 Introduction 244
10.2 Standards of Measurement 245
10.3 Allowance and Tolerance 252
10.4 Inspection Methods for Measurement 261
10.5 Measuring Instruments 263
10.6 Vision Systems for Measurement 275
10.7 Coordinate Measuring Machines 279
10.8 Angle Measuring Instruments 282
10.9 Gages for Attributes Measuring 283
10.10 Surface Roughness Measurement 288
Chapter 11 Nondestructive
Inspection and Testing 299
11.1 Destructive versus Nondestructive Testing 299
11.2 Visual Inspection 301
11.3 Liquid Penetrant Inspection 302
11.4 Magnetic Particle Inspection 303
11.5 Ultrasonic Inspection 305
11.6 Radiography 308
11.7 Eddy Current Testing 310
11.8 Acoustic Emission Monitoring 312
11.9. Other Methods of Nondestructive Testing
and Inspection 313
11.10 Dormant versus Critical Flaws 315
Case Study: Portable Failure Analysis Kit 316
Chapter 12 Process Capability
and Quality Control 317
12.1 Introduction 317
12.2 Determining Process Capability 317
12.3 Inspection and Quality Control 326
12.4 Determining Causes for Problems in Quality 334
Part 3 Casting
Processes 339
Chapter 13 Fundamentals
of Casting 340
13.1 Introduction to Materials Processing 340
13.2 Introduction to Casting 342
13.3 Casting Terminology 343
13.4 The Solidification Process 344
13.5 Patterns 355
13.6 Design Considerations in Casting 358
Case Study: The Cast Oil Field Fitting 364
Chapter 14 Expendable Mold
Casting Processes 365
14.1. Introduction 365
14.2. Sand Casting 366
14.3 Cores and Core Making 383
14.4 Other Expendable Mold Processes
with Multiple Use Patterns 387
14.5 Expendable Mold Processes
Using Single Use Patterns 390
14.6 Summary 396
Case Study: Moveable and Fixed Jaw Pieces
for a Heavy Duty Bench Vise 398
Chapter 15 Multiple Use Mold
Casting Processes 399
15.1 Introduction 399
15.2 Permanent Mold Casting 399
15.3 Die Casting 403
15.4 Squeeze Casting
(or Liquid Metal Forging) 408
15.5 Centrifugal Casting 408
15.6 Semicentrifugal Casting 409
15.7 Centrifuging 411
15.8 Continuous Casting 411
15.9 Electromagnetic (or Levitation) Casting 411
15.10 Melting and Pouring 412
15.11 Pouring Practice 416
15.12 Cleaning, Finishing, and Heat Treating
of Castings 417
15.13 Robots in Foundry Operations 419
15.14 Process Selection 419
Case Study: Baseplate for a Household Steam Iron 422
Chapter 16 Powder
Metallurgy 423
16.1 Introduction 423
16.2 Basic Process 424
16.3 Powder Manufacture 424
16.4 Rapidly Solidified Powder
(Microcrystalline and Amorphous) 426
16.5 Powder Testing and Evaluation 426
16.6 Powder Mixing and Blending 426
16.7 Compacting 427
16.8 Sintering 432
16.9 Hot Isostatic Pressing 433
16.10 Other Techniques to Produce
High Density P/M Products 434
16.11 Secondary Operations 434
16.12 Properties of P/M Products 436
16.13 Design of Powder Metallurgy Parts 437
16.14 Powder Metallurgy Products 438
16.15 Advantages and Disadvantages
of Powder Metallurgy 440
Case Study: Automobile Seat Adjustment Gears 444
Contents V
Part 4 Forming
Processes 445
Chapter 17 Fundamentals
of Metal Forming 446
17.1 Introduction 446
17.2 Forming Processes: Independent Variables 447
17.3 Dependent Variables 449
17.4 Independent Dependent Relationships 450
17.5 General Parameters 451
17.6 Friction and Lubrication under Metalworking
Conditions 452
17.7 Temperature Concerns 454
Case Study: Repairs to a Damaged Propeller 463
Chapter 18 Hot Working
Processes 464
18.1 Introduction 464
18.2 Classification of Deformation Processes 464
18.3 Hot Working Processes 465
18.4 Rolling 465
18.5 Forging 472
18.6 Extrusion 484
18.7 Hot Drawing of Sheet and Plate 490
18.8 Pipe Welding 491
18.9 Piercing 491
Case Study: Outboard Motor Brackets 495
Chapter 19 Cold Working
Processes 496
19.1 Introduction 496
19.2 Squeezing Processes 497
19.3 Bending 509
19.4 Shearing Operations 518
19.5 Drawing and Sheet Metal Forming 528
19.6 Alternative Methods of Producing
Sheet Type Products 545
19.7 Presses 546
Case Study: The Bronze Bolt Mystery 555
Chapter 20 Fabrication of Plastics,
Ceramics, and Composites 556
20.1 Introduction 556
20.2 Fabrication of Plastics 557
20.3 Processing of Rubber and Elastomers 571
20.4 Processing of Ceramics 572
20.5 Fabrication of Composite Materials 576
Case Study: Fabrication of Lavatory Wash Basins 588
vi Contents
Part 5 Material Removal
Processes 589
Chapter 21 Fundamentals
of Chip Type Machining
Processes 590
21.1 Introduction 590
21.2 Basic Chip Formation Processes 590
21.3 Understanding Chip Formation 599
21.4 Orthogonal Machining 601
21.5 Energy and Power in Machining 607
21.6 Heat and Temperature in Metal Cutting 611
21.7 Summary 612
Case Study: HSS versus Tungsten Carbide 617
Chapter 22 Cutting Tools
for Machining 618
22.1 Introduction 618
22.2 Cutting Tool Materials 619
22.3 Tool Geometry 635
22.4 Tool Failure and Tool Life 637
22.5 Reconditioning Cutting Tools 643
22.6 Economics of Machining 643
22.7 Machinability 646
22.8 Cutting Fluids 647
Case Study: Indexable Drill Insert 652
Chapter 23 Turning, Boring,
and Related Processes 653
23.1 Introduction 653
23.2 Fundamentals of Turning, Boring, and Facing 655
23.3 Lathe Design and Terminology 665
23.4 Types of Boring Machines 677
23.5 Cutting Tools for Lathes 682
23.6 Workholding in Lathes 687
Case Study: Break Even Point Analysis
of a Lathe Part 695
Chapter 24 Drilling and Related
Hole Making Processes 696
24.1 Introduction 696
24.2 Fundamentals of the Drilling Process 697
24.3 Types of Drills 700
24.4 Toolholders for Drills 709
24.5 Workholding Devices for Drilling 710
24.6 Machine Tools for Drilling 711
24.7 Cutting Fluids for Drilling 716
24.8 Counterboring, Countersinking,
and Spot Facing 717
24.9 Drilling Practice and Problems 720
24.10 Reaming 720
Case Study: Bolt Down Leg on a Casting 725
Chapter 25 Milling 726
25.1 Introduction 726
25.2 Fundamentals of Milling Processes 726
25.3 Milling Cutters 732
25.4 Milling Machines 737
25.5 Workholding Devices for Milling 745
25.6 Milling Tolerances 745
25.7 Milling Surface Finish 746
Chapter 26 Broaching, Sawing,
Filing, Shaping, and Planing 748
26.1 Introduction to Broaching 748
26.2 Fundamentals of Broaching 749
26.3 Broaching Machines 756
26.4 Introduction to Sawing 759
26.5 Saw Blades 761
26.6 Types of Sawing Machines 764
26.7 Filing 769
26.8 Types of Files 769
26.9 Filing Machines 771
26.10 Shaping and Planing 772
26.11 Planing Machines 778
Case Study: Socket with a Triangular Hole 782
Chapter 27 Abrasive
Machining Processes 783
27.1 Introduction 783
27.2 Abrasives 785
27.3 Grinding 788
27.4 Grinding Machines 798
27.5 Design Considerations in Grinding 810
27.6 Honing 811
27.7 Superfinishing 812
27.8 Lapping 813
Case Study: Aluminum Retainer Rings 815
Chapter 28 Workholding
Devices 816
28.1 Introduction 816
28.2 Conventional Fixture Design 817
28.3 Design Criteria for Workholders 818
28.4 Design Steps 819
28.5 Clamping Considerations 821
28.6 Example of Jig Design 822
28.7 Chip Disposal 824
28.8 Unloading and Loading Time 824
28.9 Setup and Changeover 827
28.10 Types of Jigs 827
28.11 Examples of Conventional Fixtures 829
28.12 Clamps 832
28.13 Modular Fixturing 833
28.14 Group Jig and Fixture 834
28.15 Other Workholding Devices 838
28.16 Economic Justification of Jigs and Fixtures 840
Case Study: Overhead Crane Installation 845
Chapter 29 Numerical Control
and Machining Centers 846
29.1 Introduction 846
29.2 CAD NC versus APT 852
29.3 A(4) versus A(5) Level of Automation 852
29.4 Numerical Control versus Conventional
Machine Tools 854
29.5 Basic Principles of Numerical Control 855
29.6 Machining Center Features and Trends 869
29.7 Advantages of Numerical Control 874
29.8 Economic Considerations in Numerical Control 874
Case Study: Break Even Point Analysis
of a Lathe Part 878
Chapter 30 Thread
Manufacturing 880
30.1 Introduction 880
30.2 Thread Cutting 886
30.3 Internal Thread Cutting 891
30.4 Thread Milling 899
30.5 Thread Grinding 899
30.6 Thread Rolling 900
Case Study: Vented Cap Screws 905
Chapter 31 Gear
Manufacturing 906
31.1 Introduction 906
31.2 Gear Types 910
31.3 Gear Manufacturing 912
31.4 Machining of Gears 913
31.5 Gear Finishing 927
31.6 Gear Inspection 930
Case Study: Six Second Pinion Gear 933
Contents VH
Chapter 32 Nontraditional
Machining Processes 935
32.1 Introduction 935
32.2 Chemical NTM Processes 941
32.3 Electrochemical NTM Processes 947
32.4 Mechanical NTM Processes 952
32.5 Thermal Processes 955
Part 6 Joining
Processes 965
Chapter 33 Gas Flame Processes:
Welding, Cutting,
and Straightening 966
33.1 Overview of Welding Processes 966
33.2 Oxyfuel Gas Welding 968
33.3 Overview of Cutting Processes 971
33.4 Oxygen Torch Cutting 972
33.5 Flame Straightening 975
Chapter 34 Arc Processes:
Welding and Cutting 978
34.1 Arc Welding 978
34.2 Arc Cutting 993
34.3 Metallurgical and Heat Considerations
in Thermal Cutting 996
Case Study: Repair of a Bicycle Frame 998
Chapter 35 Resistance
Welding 999
35.1 Theory of Resistance Welding 999
35.2 Resistance Welding Processes 1002
35.3 Advantages and Limitations 1008
Chapter 36 Other Welding
and Related Processes 1010
36.1 Introduction 1010
36.2 Solid State Welding Processes 1010
36.3 Other Welding and Cutting Processes 1016
36.4 Welding of Plastics 1024
36.5 Welding Related Processes 1028
Case Study: Field Repair
to a Power Transformer Case 1033
Chapter 37 Brazing
and Soldering 1034
37.1 Introduction 1034
37.2 Brazing 1034
VMi Contents
37.3 Soldering 1045
Case Study: The Industrial Disposal Impeller 1050
Chapter 38 Adhesive Bonding
and Mechanical Fasteners 1051
38.1 Adhesive Bonding 1051
38.2 Mechanical Fastening 1059
Case Study: Golf Club Heads 1065
Chapter 39 Manufacturing
Concerns in Welding
and Joining 1066
39.1 Introduction 1066
39.2 Types of Fusion Welds and Types of Joints 1066
39.3 Design Considerations 1068
39.4 Heat Effects 1070
39.5 Weldability or Joinability 1077
39.6 Summary 1077
Case Study: The Welded Frame 1080
Part 7 Processes
and Techniques Related
to Manufacturing 1081
Chapter 40 Surface Treatments
and Finishing 1082
40.1 Introduction 1082
40.2 Mechanical Cleaning and Finishing 1083
40.3 Chemical Cleaning 1090
40.4 Burr Removal 1093
40.5 Coatings 1096
40.6 Vaporized Metal Coatings 1105
40.7 Ion Implantation 1108
40.8 Clad Materials 1109
40.9 Textured Surfaces 1109
40.10 Coil coated Sheets 1110
40.11 Effects of Surface Processing 1110
Case Study: Burrs on Yo gi s Collar 1116
Chapter 41 Manufacturing
Systems and Automation 1117
41.1 Introduction 1117
41.2 Trends in Manufacturing Systems 1118
41.3 How the First Manufacturing System Evolved 1119
41.4 Systems Defined 1119
41.5 Manufacturing versus Production Systems 1120
41.6 Classification of Manufacturing Systems 1121
41.7 Automation 1134
41.8 Robotics 1149
41.9 Summary 1161
Chapter 42 Production
Systems 1164
42.1 Introduction 1164
42.2 Typical Functional Areas 1165
42.3 Computer Integrated Manufacturing 1189
42.4 Summary 1195
Case Study: Underground Steam Line 1198
Chapter 43 Lean Production:
JIT Manufacturing Systems 1199
44.1 Introduction 1199
44.2 Ten Steps to Lean Production 1200
44.3 Design of the Linked Cell Factory 1202
44.4 How to Design Manufacturing Cells 1207
44.5 Setup Reduction 1211
44.6 Integrated Quality Control 1214
44.7 Integrated Preventive Maintenance 1216
44.8 Leveling and Balancing
the Manufacturing System 1216
44.9 Linking the Cells 1217
44.10 Reducing the Work in Process 1219
44.11 Vendor Relationships 1219
44.12 Autonomation 1221
44.13 Restructuring the Rest of the Business 1222
44.14 Benefits of Conversion 1223
44.15 Constraints to Conversion 1223
44.16 Summary 1224
Case Study: Snowmobile Accident 1227
Appendix Additional Case
Studies 1228
Bibliography 1238
Index 1241
|
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| id | DE-604.BV011484100 |
| illustrated | Illustrated |
| indexdate | 2024-07-09T18:10:32Z |
| institution | BVB |
| isbn | 0023286210 |
| language | English |
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| physical | XI, 1259 S. Ill., graph. Darst. |
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| publisher | Prentice Hall |
| record_format | marc |
| spelling | De Garmo, Ernest P. Verfasser aut Materials and processes in manufacturing E. Paul DeGarmo ; J. T. Black ; Ronald A. Kohser 8. ed. Upper Saddle River, NJ Prentice Hall 1997 XI, 1259 S. Ill., graph. Darst. txt rdacontent n rdamedia nc rdacarrier Manufacturing processes Materials Fertigungstechnik (DE-588)4329079-6 gnd rswk-swf Fertigungstechnik (DE-588)4329079-6 s DE-604 Black, J. T. Verfasser aut Kohser, Ronald A. Verfasser aut HBZ Datenaustausch application/pdf http://bvbr.bib-bvb.de:8991/F?func=service&doc_library=BVB01&local_base=BVB01&doc_number=007726157&sequence=000002&line_number=0001&func_code=DB_RECORDS&service_type=MEDIA Inhaltsverzeichnis |
| spellingShingle | De Garmo, Ernest P. Black, J. T. Kohser, Ronald A. Materials and processes in manufacturing Manufacturing processes Materials Fertigungstechnik (DE-588)4329079-6 gnd |
| subject_GND | (DE-588)4329079-6 |
| title | Materials and processes in manufacturing |
| title_auth | Materials and processes in manufacturing |
| title_exact_search | Materials and processes in manufacturing |
| title_full | Materials and processes in manufacturing E. Paul DeGarmo ; J. T. Black ; Ronald A. Kohser |
| title_fullStr | Materials and processes in manufacturing E. Paul DeGarmo ; J. T. Black ; Ronald A. Kohser |
| title_full_unstemmed | Materials and processes in manufacturing E. Paul DeGarmo ; J. T. Black ; Ronald A. Kohser |
| title_short | Materials and processes in manufacturing |
| title_sort | materials and processes in manufacturing |
| topic | Manufacturing processes Materials Fertigungstechnik (DE-588)4329079-6 gnd |
| topic_facet | Manufacturing processes Materials Fertigungstechnik |
| url | http://bvbr.bib-bvb.de:8991/F?func=service&doc_library=BVB01&local_base=BVB01&doc_number=007726157&sequence=000002&line_number=0001&func_code=DB_RECORDS&service_type=MEDIA |
| work_keys_str_mv | AT degarmoernestp materialsandprocessesinmanufacturing AT blackjt materialsandprocessesinmanufacturing AT kohserronalda materialsandprocessesinmanufacturing |