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- ISBN: 9780136081685 | 0136081681
- Cover: Hardcover
- Copyright: 3/27/2009
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An up-to-date text that provides a solid background in manufacturing processes, with a total of 120 examples and case studies, current and comprehensive coverage of all topics, and superior two-color graphics. The sixth edition has been completely updated, and addresses issues essential to modern manufacturing, ranging from traditional topics such as casting, forming, machining, and joining, to advanced topics such as the fabrication of microelectronic devices and microelectromechanical systems (MEMS), and nanomaterials and nanomanufacturing. A valuable reference text for manufacturing professionals.
Professor Serope Kalpakjian has been teaching at the Illinois Institute of Technology since 1963. After graduating from Robert College (with High Honors), Harvard University, and the Massachusetts Institute of Technology, he joined Cincinnati Milacron, Inc., where he was a research supervisor in charge of advanced metal-forming processes. He has published numerous papers and is the author of several articles in encyclopedias and handbooks; he has also edited various volumes and serves on the editorial boards of several journals and the Encyclopedia Americana.
He is the author of three additional manufacturing books, two of which received the M. Eugene Merchant Manufacturing Textbook Award. He is a Life Fellow of the American Society of Mechanical Engineers, Fellow and Life Member of ASM International, and Fell of the Society of Manufacturing Engineers, and is a full member (Emeritus) of the International Institution for Production Engineering Research (CIRP). He is a founding member and a past president of the North American manufacturing Research Institution.
Professor Kalpakjian has received several awards: Citation by the Forging Industry Educational and Research Foundation for best paper (1966); Citation by the Society of Carbide and Tool Engineers (1977); The "Excellence in Teaching Award" from the Illinois Institute of Technology (1970); the "Centennial Medallion" by the American Society of Mechanical Engineers (1980); the International "Education Award" by the Society of Manufacturing Engineers (1989); and the Albert Easton White Distinguished Teacher Award by the American Society for Metals International (2000).
Dr. Steven R. Schmid is an Associate Professor in the Department of Aerospace and Mechanical Engineering at the University of Notre Dame, where he teaches and conducts research in manufacturing, machine design, and tribology. As the Director of the Manufacturing Tribology Laboratory at the university, he oversees industry and governmentally funded research on a wide variety of manufacturing topics, including tribological issues in rolling, forging and sheet metal forming, polymer processing, medical device design and manufacture, and nanomechanics.
He received his Bachelor's degree in Mechanical Engineering from the Illinois Institute of Technology (with Honors) and Master's and Ph.D. degrees, both in Mechanical Engineering, from Northwestern University. Dr. Schmid is the recipient of a National Science Foundation CAREERS Award and an ALCOA Foundation Young Faculty Award. He has been a leading proponent for the integration of research and engineering education; NSF has sponsored workshops on this issue for which he has served as head of the steering committee.
He is the author of over thirty technical papers in various journals, has edited three conference proceedings, has co-authored "Fundamentals of Machine Elements," and has contributed two chapters to the CRC "Handbook of Modern Tribology." He serves on the Tribology Division Executive Committee of the American Society of Mechanical Engineers, and has held officer positions in the Society of Manufacturing Engineers and the Society of Tribology and Lubrication Engineers. He is a registered Professional Engineer an a Certified Manufacturing Engineer.
General Introduction 1
I.1 What Is Manufacturing? 1
I.2 Product Design and Concurrent Engineering 8
I.3 Design for Manufacture, Assembly, Disassembly, and Service 11
I.4 Green Design and Manufacturing 13
I.5 Selection of Materials 15
I.6 Selection of Manufacturing Processes 18
I.7 Computer-integrated Manufacturing 26
I.8 Quality Assurance and Total Quality Management 29
I.9 Lean Production and Agile Manufacturing 32
I.10 Manufacturing Costs and Global Competition 32
I.11 General Trends in Manufacturing 34
Part I: Fundamentals of Materials: Their Behavior
and Manufacturing Properties 37
1 The Structure of Metals 40
1.1 Introduction 40
1.2 Types of Atomic Bonds 41
1.3 The Crystal Structure of Metals 42
1.4 Deformation and Strength of Single Crystals 44
1.5 Grains and Grain Boundaries 47
1.6 Plastic Deformation of Polycrystalline Metals 50
1.7 Recovery, Recrystallization, and Grain Growth 51
1.8 Cold, Warm, and Hot Working 52
Summary 53 Key Terms 53 Bibliography 54
Review Questions 54 Qualitative Problems 54
Quantitative Problems 55 Synthesis, Design, and Projects 55
2 Mechanical Behavior, Testing, and
Manufacturing Properties of Materials 56
2.1 Introduction 56
2.2 Tension 57
2.3 Compression 66
2.4 Torsion 67
2.5 Bending (Flexure) 68
2.6 Hardness 68
2.7 Fatigue 74
2.8 Creep 75
2.9 Impact 75
2.10 Failure and Fracture of Materials in Manufacturing
and in Service 76
2.11 Residual Stresses 81
2.12 Work, Heat, and Temperature 82
Summary 83 Key Terms 84 Bibliography 84
Review Questions 84 Qualitative Problems 85
Quantitative Problems 85 Synthesis, Design, and Projects 86
3 Physical Properties of Materials 88
3.1 Introduction 88
3.2 Density 89
3.3 Melting Point 92
3.4 Specific Heat 92
3.5 Thermal Conductivity 93
3.6 Thermal Expansion 93
3.7 Electrical, Magnetic, and Optical Properties 94
3.8 Corrosion Resistance 95
Summary 97 Key Terms 97 Bibliography 98
Review Questions 98 Qualitative Problems 98
Quantitative Problems 98 Synthesis, Design, and Projects 99
4 Metal Alloys: Their Structure and Strengthening
by Heat Treatment 100
4.1 Introduction 100
4.2 Structure of Alloys 101
4.3 Phase Diagrams 103
4.4 The Iron—Carbon System 107
4.5 The Iron—Iron-carbide Phase Diagram and the Development
of Microstructures in Steels 108
4.6 Cast Irons 110
4.7 Heat Treatment of Ferrous Alloys 111
4.8 Hardenability of Ferrous Alloys 115
4.9 Heat Treatment of Nonferrous Alloys and
Stainless Steels 117
4.10 Case Hardening 119
4.11 Annealing 121
4.12 Heat-treating Furnaces and Equipment 123
4.13 Design Considerations for Heat Treating 125
Summary 126 Key Terms 127 Bibliography 127
Review Questions 127 Qualitative Problems 127
Quantitative Problems 128 Synthesis, Design, and Projects 128
5 Ferrous Metals and Alloys: Production, General
Properties, and Applications 129
5.1 Introduction 129
5.2 Production of Iron and Steel 130
5.3 Casting of Ingots 133
5.4 Continuous Casting 134
5.5 Carbon and Alloy Steels 136
5.6 Stainless Steels 143
5.7 Tool and Die Steels 145
Summary 147 Key Terms 148 Bibliography 148
Review Questions 148 Qualitative Problems 149
Quantitative Problems 149 Synthesis, Design, and Projects 150
6 Nonferrous Metals and Alloys: Production,
General Properties, and Applications 151
6.1 Introduction 151
6.2 Aluminum and Aluminum Alloys 152
6.3 Magnesium and Magnesium Alloys 157
6.4 Copper and Copper Alloys 158
6.5 Nickel and Nickel Alloys 160
6.6 Superalloys 161
6.7 Titanium and Titanium Alloys 162
6.8 Refractory Metals and Alloys 163
6.9 Beryllium 164
6.10 Zirconium 164
6.11 Low-melting Alloys 164
6.12 Precious Metals 166
6.13 Shape-memory Alloys (Smart Materials) 166
6.14 Amorphous Alloys (Metallic Glasses) 167
6.15 Metal Foams 167
Summary 168 Key Terms 168 Bibliography 169
Review Questions 169 Qualitative Problems 169
Quantitative Problems 170 Synthesis, Design, and Projects 170
7 Polymers: Structure, General Properties,
and Applications 171
7.1 Introduction 171
7.2 The Structure of Polymers 173
7.3 Thermoplastics 180
7.4 Thermosetting Plastics 184
7.5 Additives in Plastics 184
7.6 General Properties and Applications of Thermoplastics 185
7.7 General Properties and Applications of Thermosetting
Plastics 188
7.8 Biodegradable Plastics 190
7.9 Elastomers (Rubbers) 191
Summary 192 Key Terms 193 Bibliography 193
Review Questions 194 Qualitative Problems 194
Quantitative Problems 195 Synthesis, Design, and Projects 195
8 Ceramics, Graphite, Diamond, and
Nanomaterials: Structure, General Properties,
and Applications 196
8.1 Introduction 196
8.2 The Structure of Ceramics 197
8.3 General Properties and Applications of Ceramics 201
8.4 Glasses 205
8.5 Glass Ceramics 207
8.6 Graphite 208
8.7 Diamond 210
8.8 Nanomaterials 210
Summary 212 Key Terms 212 Bibliography 213
Review Questions 213 Qualitative Problems 214
Quantitative Problems 214 Synthesis, Design, and Projects 214
9 Composite Materials: Structure, General
Properties, and Applications 216
9.1 Introduction 216
9.2 The Structure of Reinforced Plastics 217
9.3 Properties of Reinforced Plastics 222
9.4 Applications of Reinforced Plastics 225
9.5 Metal-matrix Composites 227
9.6 Ceramic-matrix Composites 229
9.7 Other Composites 230
Summary 231 Key Terms 231 Bibliography 231
Review Questions 232 Qualitative Problems 232
Quantitative Problems 233 Synthesis, Design, and Projects 233
Part II: Metal-Casting Processes
and Equipment 235
1 0 Fundamentals of Metal Casting 237
10.1 Introduction 237
10.2 Solidification of Metals 238
10.3 Fluid Flow 243
10.4 Fluidity of Molten Metal 245
10.5 Heat Transfer 247
10.6 Defects 249
Summary 253 Key Terms 254 Bibliography 254
Review Questions 254 Qualitative Problems 255
Quantitative Problems 255 Synthesis, Design, and Projects 256
11 Metal-Casting Processes and Equipment 258
11.1 Introduction 258
11.2 Expendable-mold, Permanent-pattern Casting Processes 262
11.3 Expendable-mold, Expendable-pattern Casting Processes 270
11.4 Permanent-mold Casting Processes 277
11.5 Casting Techniques for Single-crystal Components 285
11.6 Rapid Solidification 286
11.7 Inspection of Castings 287
11.8 Melting Practice and Furnaces 287
11.9 Foundries and Foundry Automation 289
Summary 289 Key Terms 290 Bibliography 290
Review Questions 291 Qualitative Problems 291
Quantitative Problems 292 Synthesis, Design, and Projects 292
12 Metal Casting: Design, Materials,
and Economics 294
12.1 Introduction 294
12.2 Design Considerations in Casting 294
12.3 Casting Alloys 302
12.4 Economics of Casting 307
Summary 308 Key Terms 309 Bibliography 309
Review Questions 309 Qualitative Problems 309
Quantitative Problems 310 Synthesis, Design, and Projects 310
Part III: Forming and Shaping Processes
and Equipment 313
13 Metal-Rolling Processes and Equipment 316
13.1 Introduction 316
13.2 The Flat-rolling Process 318
13.3 Flat-rolling Practice 322
13.4 Rolling Mills 325
13.5 Various Rolling Processes and Mills 327
Summary 332 Key Terms 333 Bibliography 333
Review Questions 333 Qualitative Problems 333
Quantitative Problems 334 Synthesis, Design, and Projects 334
14 Metal-Forging Processes and Equipment 335
14.1 Introduction 335
14.2 Open-die Forging 337
14.3 Impression-die and Closed-die Forging 339
14.4 Various Forging Operations 343
14.5 Forgeability of Metals; Forging Defects 348
14.6 Die Design, Die Materials, and Lubrication 349
14.7 Die-manufacturing Methods and Die Failures 351
14.8 Forging Machines 353
14.9 Economics of Forging 355
Summary 357 Key Terms 358 Bibliography 358
Review Questions 358 Qualitative Problems 358
Quantitative Problems 359 Synthesis, Design, and Projects 359
15 Metal Extrusion and Drawing Processes
and Equipment 360
15.1 Introduction 360
15.2 The Extrusion Process 362
15.3 Hot Extrusion 364
15.4 Cold Extrusion 368
15.5 Extrusion Defects 371
15.6 Extrusion Equipment 373
15.7 The Drawing Process 373
15.8 Drawing Practice 375
15.9 Drawing Defects and Residual Stresses 377
15.10 Drawing Equipment 377
Summary 378 Key Terms 378 Bibliography 379
Review Questions 379 Qualitative Problems 379
Quantitative Problems 380 Synthesis, Design, and Projects 380
16 Sheet-Metal Forming Processes and
Equipment 381
16.1 Introduction 381
16.2 Shearing 382
16.3 Sheet-metal Characteristics and Formability 392
16.4 Formability Tests for Sheet Metals 394
16.5 Bending Sheets, Plates, and Tubes 397
16.6 Miscellaneous Bending and Related Operations 401
16.7 Deep Drawing 407
16.8 Rubber Forming and Hydroforming 413
16.9 Spinning 417
16.10 Superplastic Forming 420
16.11 Specialized Forming Processes 421
16.12 Manufacturing of Metal Honeycomb Structures 426
16.13 Design Considerations in Sheet-metal Forming 428
16.14 Equipment for Sheet-metal Forming 430
16.15 Economics of Sheet-forming Operations 431
Summary 432 Key Terms 433 Bibliography 433
Review Questions 434 Qualitative Problems 434
Quantitative Problems 435 Synthesis, Design, and Projects 435
17 Powder-Metal Processing and Equipment 437
17.1 Introduction 437
17.2 Production of Metal Powders 438
17.3 Compaction of Metal Powders 444
17.4 Sintering 452
17.5 Secondary and Finishing Operations 456
17.6 Design Considerations 457
17.7 Process Capabilities 459
17.8 Economics of Powder Metallurgy 460
Summary 462 Key Terms 462 Bibliography 463
Review Questions 463 Qualitative Problems 463
Quantitative Problems 464 Synthesis, Design, and Projects 464
18 Ceramics, Glasses, and Superconductors:
Processing and Equipment 465
18.1 Introduction 465
18.2 Shaping Ceramics 466
18.3 Forming and Shaping of Glass 472
18.4 Techniques for Strengthening and Annealing Glass 476
18.5 Design Considerations for Ceramics and Glasses 478
18.6 Processing of Superconductors 479
Summary 480 Key Terms 481 Bibliography 481
Review Questions 482 Qualitative Problems 482
Quantitative Problems 482 Synthesis, Design, and Projects 483
19 Plastics and Composite Materials: Forming
and Shaping 484
19.1 Introduction 484
19.2 Extrusion 486
19.3 Injection Molding 493
19.4 Blow Molding 499
19.5 Rotational Molding 501
19.6 Thermoforming 502
19.7 Compression Molding 503
19.8 Transfer Molding 504
19.9 Casting 505
19.10 Foam Molding 506
19.11 Cold Forming and Solid-phase Forming 507
19.12 Processing Elastomers 507
19.13 Processing Polymer-matrix Composites 508
19.14 Processing Metal-matrix and Ceramic-matrix Composites 517
19.15 Design Considerations 518
19.16 Economics of Processing Plastics and Composite Materials 520
Summary 521 Key Terms 522 Bibliography 522
Review Questions 523 Qualitative Problems 523
Quantitative Problems 524 Synthesis, Design, and Projects 524
20 Rapid-Prototyping Processes and
Operations 525
20.1 Introduction 525
20.2 Subtractive Processes 528
20.3 Additive Processes 530
20.4 Virtual Prototyping 541
20.5 Direct Manufacturing and Rapid Tooling 542
Summary 549 Key Terms 549 Bibliography 549
Review Questions 550 Qualitative Problems 550
Quantitative Problems 550 Synthesis, Design, and Projects 551
Part IV: Machining Processes
and Machine Tools 553
21 Fundamentals of Machining 556
21.1 Introduction 556
21.2 Mechanics of Cutting 558
21.3 Cutting Forces and Power 568
21.4 Temperatures in Cutting 571
21.5 Tool Life: Wear and Failure 574
21.6 Surface Finish and Integrity 581
21.7 Machinability 583
Summary 587 Key Terms 588 Bibliography 588
Review Questions 588 Qualitative Problems 589
Quantitative Problems 589 Synthesis, Design, and Projects 590
22 Cutting-Tool Materials and Cutting Fluids 591
22.1 Introduction 591
22.2 High-speed Steels 595
22.3 Cast-cobalt Alloys 596
22.4 Carbides 596
22.5 Coated Tools 600
22.6 Alumina-based Ceramics 604
22.7 Cubic Boron Nitride 605
22.8 Silicon-nitride-based Ceramics 605
22.9 Diamond 605
22.10 Whisker-reinforced Materials and Nanomaterials 606
22.11 Tool Costs and Reconditioning of Tools 607
22.12 Cutting Fluids 607
Summary 612 Key Terms 612 Bibliography 613
Review Questions 613 Qualitative Problems 613
Quantitative Problems 614 Synthesis, Design, and Projects 614
23 Machining Processes: Turning and Hole
Making 615
23.1 Introduction 615
23.2 The Turning Process 618
23.3 Lathes and Lathe Operations 626
23.4 Boring and Boring Machines 641
23.5 Drilling, Drills, and Drilling Machines 643
23.6 Reaming and Reamers 652
23.7 Tapping and Taps 653
Summary 655 Key Terms 656 Bibliography 656
Review Questions 656 Qualitative Problems 657
Quantitative Problems 657 Synthesis, Design, and Projects 658
24 Machining Processes: Milling, Broaching, Sawing,
Filing, and Gear Manufacturing 659
24.1 Introduction 659
24.2 Milling and Milling Machines 660
24.3 Planing and Shaping 674
24.4 Broaching and Broaching Machines 675
24.5 Sawing 678
24.6 Filing 681
24.7 Gear Manufacturing by Machining 681
Summary 689 Key Terms 690 Bibliography 690
Review Questions 690 Qualitative Problems 691
Quantitative Problems 691 Synthesis, Design, and Projects 692
25 Machining Centers, Machine-Tool Structures,
and Machining Economics 693
25.1 Introduction 693
25.2 Machining Centers 694
25.3 Machine-tool Structures 702
25.4 Vibration and Chatter in Machining Operations 706
25.5 High-speed Machining 709
25.6 Hard Machining 711
25.7 Ultraprecision Machining 711
25.8 Machining Economics 713
Summary 717 Key Terms 717 Bibliography 717
Review Questions 717 Qualitative Problems 718
Quantitative Problems 718 Synthesis, Design, and Projects 718
26 Abrasive Machining and Finishing
Operations 719
26.1 Introduction 719
26.2 Abrasives and Bonded Abrasives 721
26.3 The Grinding Process 727
26.4 Grinding Operations and Machines 736
26.5 Design Considerations for Grinding 744
26.6 Ultrasonic Machining 744
26.7 Finishing Operations 746
26.8 Deburring Operations 750
26.9 Economics of Abrasive Machining and Finishing Operations 753
Summary 754 Key Terms 755 Bibliography 755
Review Questions 756 Qualitative Problems 756
Quantitative Problems 757 Synthesis, Design, and Projects 757
27 Advanced Machining Processes 759
27.1 Introduction 759
27.2 Chemical Machining 761
27.3 Electrochemical Machining 765
27.4 Electrochemical Grinding 768
27.5 Electrical-discharge Machining 769
27.6 Laser-beam Machining 774
27.7 Electron-beam Machining 777
27.8 Water-jet Machining 778
27.9 Abrasive-jet Machining 779
27.10 Hybrid Machining Systems 780
27.11 Economics of Advanced Machining Processes 781
Summary 784 Key Terms 784 Bibliography 784
Review Questions 785 Qualitative Problems 785
Quantitative Problems 785 Synthesis, Design, and Projects 786
Part V: Micromanufacturing and Fabrication of
Microelectronic Devices 787
28 Fabrication of Microelectronic Devices 790
28.1 Introduction 790
28.2 Clean Rooms 793
28.3 Semiconductors and Silicon 794
28.4 Crystal Growing and Wafer Preparation 795
28.5 Film Deposition 798
28.6 Oxidation 799
28.7 Lithography 800
28.8 Etching 808
28.9 Diffusion and Ion Implantation 816
28.10 Metallization and Testing 818
28.11 Wire Bonding and Packaging 820
28.12 Yield and Reliability 825
28.13 Printed Circuit Boards 826
Summary 827 Key Terms 828 Bibliography 828
Review Questions 829 Qualitative Problems 829
Quantitative Problems 830 Synthesis, Design, and Projects 830
29 Fabrication of Microelectromechanical Devices
and Systems and Nanoscale Manufacturing 831
29.1 Introduction 831
29.2 Micromachining of MEMS Devices 833
29.3 The LIGA Microfabrication Process 844
29.4 Solid Free-form Fabrication of Devices 850
29.5 Nanoscale Manufacturing 855
Summary 858 Key Terms 858 Bibliography 858
Review Questions 859 Qualitative Problems 859
Quantitative Problems 860 Synthesis, Design, and Projects 860
Part VI: Joining Processes and
Equipment 861
30 Fusion-Welding Processes 865
30.1 Introduction 865
30.2 Oxyfuel—gas Welding 866
30.3 Arc-welding Processes: Nonconsumable Electrode 869
30.4 Arc-welding Processes: Consumable Electrode 873
30.5 Electrodes for Arc Welding 879
30.6 Electron-beam Welding 880
30.7 Laser-beam Welding 880
30.8 Cutting 882
30.9 The Weld Joint, Quality, and Testing 884
30.10 Joint Design and Process Selection 893
Summary 897 Key Terms 897 Bibliography 898
Review Questions 898 Qualitative Problems 898
Quantitative Problems 899 Synthesis, Design, and Projects 899
31 Solid-State Welding Processes 900
31.1 Introduction 900
31.2 Cold Welding and Roll Bonding 901
31.3 Ultrasonic Welding 902
31.4 Friction Welding 903
31.5 Resistance Welding 905
31.6 Explosion Welding 913
31.7 Diffusion Bonding 914
31.8 Economics of Welding Operations 916
Summary 918 Key Terms 919 Bibliography 919
Review Questions 919 Qualitative Problems 919
Quantitative Problems 920 Synthesis, Design, and Projects 920
32 Brazing, Soldering, Adhesive-Bonding,
and Mechanical-Fastening Processes 921
32.1 Introduction 921
32.2 Brazing 922
32.3 Soldering 926
32.4 Adhesive Bonding 931
32.5 Mechanical Fastening 939
32.6 Joining Plastics, Ceramics, and Glasses 942
32.7 Economics of Joining Operations 945
Summary 946 Key Terms 947 Bibliography 947
Review Questions 947 Qualitative Problems 948
Quantitative Problems 948 Synthesis, Design, and Projects 948
Part VII: Surface Technology 949
33 Surface Roughness and Measurement; Friction,
Wear, and Lubrication 951
33.1 Introduction 951
33.2 Surface Structure and Integrity 952
33.3 Surface Texture and Roughness 953
33.4 Friction 957
33.5 Wear 961
33.6 Lubrication 964
33.7 Metalworking Fluids and Their Selection 966
Summary 970 Key Terms 970 Bibliography 971
Review Questions 971 Qualitative Problems 971
Quantitative Problems 972 Synthesis, Design, and Projects 972
34 Surface Treatments, Coatings, and Cleaning 973
34.1 Introduction 973
34.2 Mechanical Surface Treatments 974
34.3 Mechanical Plating and Cladding 976
34.4 Case Hardening and Hard Facing 976
34.5 Thermal Spraying 977
34.6 Vapor Deposition 979
34.7 Ion Implantation and Diffusion Coating 982
34.8 Laser Treatments 982
34.9 Electroplating, Electroless Plating, and Electroforming 983
34.10 Conversion Coatings 986
34.11 Hot Dipping 987
34.12 Porcelain Enameling; Ceramic and Organic Coatings 988
34.13 Diamond Coating and Diamondlike Carbon 989
34.14 Surface Texturing 990
34.15 Painting 990
34.16 Cleaning of Surfaces 991
Summary 993 Key Terms 993 Bibliography 993
Review Questions 994 Qualitative Problems 994
Quantitative Problems 994 Synthesis, Design, and Projects 995
Part VIII: Engineering Metrology,
Instrumentation, and Quality
Assurance 997
35 Engineering Metrology and
Instrumentation 998
35.1 Introduction 998
35.2 Measurement Standards 999
35.3 Geometric Features of Parts; Analog and Digital
Measurements 1000
35.4 Traditional Measuring Methods and Instruments 1001
35.5 Modern Measuring Instruments and Machines 1008
35.6 Automated Measurement and Inspection 1011
35.7 General Characteristics and Selection of Measuring
Instruments 1012
35.8 Geometric Dimensioning and Tolerancing 1012
Summary 1017 Key Terms 1017 Bibliography 1017
Review Questions 1018 Qualitative Problems 1018
Quantitative Problems 1018 Synthesis, Design, and Projects 1019
36 Quality Assurance, Testing, and Inspection 1020
36.1 Introduction 1020
36.2 Product Quality 1021
36.3 Quality Assurance 1022
36.4 Total Quality Management 1023
36.5 Taguchi Methods 1025
36.6 The ISO and QS Standards 1029
36.7 Statistical Methods of Quality Control 1030
36.8 Statistical Process Control 1033
36.9 Reliability of Products and Processes 1039
36.10 Nondestructive Testing 1040
36.11 Destructive Testing 1044
36.12 Automated Inspection 1044
Summary 1045 Key Terms 1045 Bibliography 1046
Review Questions 1046 Qualitative Problems 1047
Quantitative Problems 1047 Synthesis, Design, and Projects 1047
Part IX: Manufacturing in a Competitive
Environment 1049
37Automation of Manufacturing Processes 1051
37.1 Introduction 1051
37.2 Automation 1053
37.3 Numerical Control 1060
37.4 Adaptive Control 1066
37.5 Material Handling and Movement 1068
37.6 Industrial Robots 1071
37.7 Sensor Technology 1077
37.8 Flexible Fixturing 1081
37.9 Assembly Systems 1083
37.10 Design Considerations for Fixturing, Assembly, Disassembly,
and Servicing 1086
37.11 Economic Considerations 1089
Summary 1089 Key Terms 1090 Bibliography 1090
Review Questions 1091 Qualitative Problems 1091
Quantitative Problems 1092 Synthesis, Design, and Projects 1092
38 Computer-Aided Manufacturing 1093
38.1 Introduction 1093
38.2 Manufacturing Systems 1094
38.3 Computer-integrated Manufacturing 1094
38.4 Computer-aided Design and Engineering 1097
38.5 Computer-aided Manufacturing 1104
38.6 Computer-aided Process Planning 1104
38.7 Computer Simulation of Manufacturing Processes
and Systems 1107
38.8 Group Technology 1108
Summary 1115 Key Terms 1115 Bibliography 1115
Review Questions 1116 Qualitative Problems 1116
Synthesis, Design, and Projects 1116
39 Computer-Integrated Manufacturing
Systems 1117
39.1 Introduction 1117
39.2 Cellular Manufacturing 1118
39.3 Flexible Manufacturing Systems 1120
39.4 Holonic Manufacturing 1122
39.5 Just-in-time Production 1124
39.6 Lean Manufacturing 1125
39.7 Communications Networks in Manufacturing 1127
39.8 Artificial Intelligence 1129
39.9 Economic Considerations 1132
Summary 1132 Key Terms 1133 Bibliography 1133
Review Questions 1134 Qualitative Problems 1134
Synthesis, Design, and Projects 1134
40 Product Design and Process Selection
in a Competitive Environment 1135
40.1 Introduction 1135
40.2 Product Design 1136
40.3 Product Quality and Life Expectancy 1139
40.4 Life-cycle Assessment and Sustainable Manufacturing 1140
40.5 Material Selection for Products 1142
40.6 Material Substitution 1146
40.7 Manufacturing Process Capabilities 1148
40.8 Process Selection 1152
40.9 Manufacturing Costs and Cost Reduction 1156
Summary 1161 Key Terms 1161 Bibliography 1162
Review Questions 1162 Qualitative Problems 1162
Synthesis, Design, and Projects 1163
Index 1165
Case Studies
11.1: Lost-foam Casting of Engine Blocks 272
11.2: Investment Casting of Total Knee Replacements 275
14.1: Manufacture of a Stepped Pin by Heading and Piercing
Operations 345
14.2: Suspension Components for the Lotus Elise Automobile 356
16.1: Manufacturing of Food and Beverage Cans 412
16.2: Tube Hydroforming of an Automotive Radiator Closure 415
16.3: Cymbal Manufacture 424
17.1: Powder Metallurgy Parts in a Snowblower 461
18.1: Production of High-temperature Superconducting Tapes 480
19.1: Manufacture of Head Protector™ Tennis Racquets 515
20.1: Invisalign® Orthodontic Aligners 543
23.1: Bone Screw Retainer 654
24.1: Ping Golf Putter 688
27.1: Electrochemical Machining of a Biomedical Implant 767
27.2: Manufacture of Small Satellites 781
29.1: Digital Micromirror Device 837
29.2: Accelerometer for Automotive Air Bags 851
31.1: Friction Welding of Pistons 917
32.1: Light Curing Acrylic Adhesives for Medical Products 937
36.1: Manufacture of Television Sets by Sony Corporation 1028
36.2: Dimensional Control of Plastic Parts in Saturn Automobiles 1038
37.1: Robotic Deburring of a Blow-molded Toboggan 1076
38.1: CAD Model Development for Automotive Components 1101
40.1: Automobile Tires: From Cradle-to-grave to Cradle-to-cradle 1141
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