Manufacturing. Engineering. and Technology. Serope Kalpakjian. K. S. Vijay Sekar. Steven R. Schmid SEVENTH EDITION IN SI UNITS.

Transcription

1 Manufacturing Engineering and Technology SEVENTH EDITION IN SI UNITS Serope Kalpakjian Illinois Institute of Technology Steven R. Schmid The University of Notre Dame SI Edition Contributions by K. S. Vijay Sekar SSN College of Engineering, Chennai, India Singapore London New York Toronto Sydney Tokyo Madrid Mexico City Munich Paris Cape Town Hong Kong Montreal

2 Contents Preface xxiii About the Authors xxvii General Introduction What is Manufacturing? 1 Product Design and Concurrent Engineering 6 Design for Manufacture, Assembly, Disassembly, and Service 10 Green Design and Manufacturing 11 Selection of Materials 13 Selection of Manufacturing Processes 16 Computer-integrated Manufacturing 25 Quality Assurance and Total Quality Management 28 Lean Production and Agile Manufacturing 30 Manufacturing Costs and Global Competition 31 Trends in Manufacturing 32 Parti: Fundamentals of Materials: Behavior and Manufacturing Properties 35 1 The Structure of Metals Introduction Types of Atomic Bonds The Crystal Structure of Metals Deformation and Strength of Single Crystals Grains and Grain Boundaries Plastic Deformation of Polycrystalline Metals Recovery, Recrystallization, and Grain Growth Cold, Warm, and Hot Working 50 Summary 51 Key Terms 51 Bibliography 52 Review Questions 52 Qualitative Problems 52 Quantitative Problems 53 Synthesis, Design, and Projects 54 Mechanical Behavior, Testing, and Manufacturing Properties of Materials Introduction Tension 56 v

3 2.3 Compression Torsion Bending (Flexure) Hardness Fatigue Creep Impact Failure and Fracture of Materials Residual Stresses Work, Heat, and Temperature 81 Summary 82 Key Terms 83 Bibliography 83 Review Questions 84 Qualitative Problems 84 Quantitative Problems 85 Synthesis, Design, and Projects 86 Physical Properties of Materials Introduction Density Melting Point Specific Heat Thermal Conductivity Thermal Expansion Electrical, Magnetic, and Optical Properties Corrosion Resistance 95 Summary 97 Key Terms 98 Bibliography 98 Review Questions 98 Qualitative Problems 98 Quantitative Problems 99 Synthesis, Design, and Projects 99 Metal Alloys: Their Structure and Strengthening by Heat Treatment Introduction Structure of Alloys Phase Diagrams The Iron-carbon System The Iron-iron-carbide Phase Diagram and the Development of Microstructures in Steels Cast Irons Heat Treatment of Ferrous Alloys Hardenability of Ferrous Alloys Heat Treatment of Nonferrous Alloys and Stainless Steels Case Hardening Annealing Heat-treating Furnaces and Equipment Design Considerations for Heat Treating 124

4 Summary 125 Key Terms 126 Bibliography 126 Review Questions 126 Qualitative Problems 127 Quantitative Problems 127 Synthesis, Design, and Projects 127 Ferrous Metals and Alloys: Production, General Properties, and Applications Introduction Production of Iron and Steel Casting of Ingots Continuous Casting Carbon and Alloy Steels Stainless Steels Tool and Die Steels 144 Summary 145 Key Terms 146 Bibliography 147 Review Questions 147 Qualitative Problems 147 Quantitative Problems 148 Synthesis, Design, and Projects 148 Nonferrous Metals and Alloys: Production, General Properties, and Applications Introduction Aluminum and Aluminum Alloys Magnesium and Magnesium Alloys Copper and Copper Alloys Nickel and Nickel Alloys Superalloys Titanium and Titanium Alloys Refractory Metals and Alloys Beryllium Zirconium Low-melting Alloys Precious Metals Shape-memory Alloys (Smart Materials) Amorphous Alloys (Metallic Glasses) Metal Foams 165 Summary 166 Key Terms 166 Bibliography 166 Review Questions 167 Qualitative Problems 167 Quantitative Problems 167 Synthesis, Design, and Projects 168 Polymers: Structure, General Properties, and Applications Introduction The Structure of Polymers Thermoplastics 178

5 viii Contents 7.4 Thermosetting Plastics Additives in Plastics General Properties and Applications of Thermoplastics General Properties and Applications of Thermosetting Plastics Biodegradable Plastics Elastomers (Rubbers) 188 Summary 189 Key Terms 190 Bibliography 190 Review Questions 191 Qualitative Problems 191 Quantitative Problems 192 Synthesis, Design, and Projects, Ceramics, Glass, Graphite, Diamond, and Nanomaterials: Structure, General Properties, and Applications Introduction The Structure of Ceramics General Properties and Applications of Ceramics Glasses Glass Ceramics Graphite Diamond Nanomaterials 210 Summary 211 Key Terms 212 Bibliography 212 Review Questions 212 Qualitative Problems 213 Quantitative Problems 213 Synthesis, Design, and Projects 213 Composite Materials: Structure, General Properties, and Applications Introduction The Structure of Reinforced Plastics Properties of Reinforced Plastics Applications of Reinforced Plastics Metal-matrix Composites Ceramic-matrix Composites Other Composites 229 Summary 230 Key Terms 230 Bibliography 230 Review Questions 231 Qualitative Problems 231 Quantitative Problems 232 Synthesis, Design, and Projects 232

6 Part II: Metal-casting Processes and Equipment Fundamentals of Metal Casting Introduction Solidification of Metals Fluid Flow Fluidity of Molten Metal Heat Transfer Defects 249 Summary 252 Key Terms 252 Bibliography 253 Review Questions 253 Qualitative Problems 253 Quantitative Problems 254 Synthesis, Design, and Projects 255 Metal-casting Processes and Equipment Introduction Expendable-mold, Permanent-pattern Casting Processes Expendable-mold, Expendable-pattern Casting Processes Permanent-mold Casting Processes Casting Techniques for Single-crystal Components Rapid Solidification Inspection of Castings Melting Practice and Furnaces Foundries and Foundry Automation 289 Summary 289 Key Terms 290 Bibliography 290 Review Questions 290 Qualitative Problems 291 Quantitative Problems 291 Synthesis, Design, and Projects Metal Casting: Design, Materials, and Economics Introduction Design Considerations in Casting Casting Alloys Economics of Casting 308 Summary 309 Key Terms 309 Bibliography 309 Review Questions 310 Qualitative Problems 310 Quantitative Problems 310 Synthesis, Design, and Projects 311

7 Contents Part III: Forming and Shaping Processes and Equipment Metal-rolling Processes and Equipment Introduction The Flat-rolling Process Flat-rolling Practice Rolling Mills Various Rolling Processes and Mills 328 Summary 333 Key Terms 333 Bibliography 334 Review Questions 334 Qualitative Problems 334 Quantitative Problems 335 Synthesis, Design, and Projects Metal-forging Processes and Equipment Introduction Open-die Forging Impression-die and Closed-die Forging Various Forging Operations Forgeability of Metals; Forging Defects Die Design, Die Materials, and Lubrication Die-manufacturing Methods and Die Failure Forging Machines Economics of Forging Summary 360 Key Terms 361 Bibliography 361 Review Questions 362 Qualitative Problems 362 Quantitative Problems 362 Synthesis, Design, and Projects 363 Metal Extrusion and Drawing Processes and Equipment Introduction The Extrusion Process Hot Extrusion Cold Extrusion Extrusion Defects Design Considerations Extrusion Equipment The Drawing Process Drawing Practice Drawing Defects and Residual Stresses Drawing Equipment 382 Summary 383 Key Terms 384 Bibliography 384 Review Questions 384 Qualitative Problems 384 Quantitative Problems 385 Synthesis, Design, and Projects 385

8 Sheet-metal Forming Processes and Equipment Introduction Shearing Sheet-metal Characteristics and Formability Formability Tests for Sheet Metals Bending Sheets, Plates, and Tubes Miscellaneous Bending and Related Forming Operations Deep Drawing Rubber Forming and Hydroforming Spinning Superplastic Forming Hot Stamping Specialized Forming Processes Manufacturing of Metal Honeycomb Structures Design Considerations in Sheet-metal Forming Equipment for Sheet-metal Forming Economics of Sheet-forming Operations 438 Summary 439 Key Terms 440 Bibliography 440 Review Questions 440 Qualitative Problems 441 Quantitative Problems 441 Synthesis, Design, and Projects 442 Powder Metal Processes and Equipment Introduction Production of Metal Powders Compaction of Metal Powders Sintering Secondary and Finishing Operations Design Considerations Economics of Powder Metallurgy 469 Summary 471 Key Terms 471 Bibliography 471 Review Questions 472 Qualitative Problems 472 Quantitative Problems 473 Synthesis, Design, and Projects 473 Ceramics, Glasses, and Superconductors: Processing and Equipment Introduction Shaping Ceramics Forming and Shaping of Glass Techniques for Strengthening and Annealing Glass Design Considerations for Ceramics and Glasses Processing of Superconductors 489

9 xii Contents Summary 491 Key Terms 491 Bibliography 492 Review Questions 492 Qualitative Problems 492 Quantitative Problems 493 Synthesis, Design, and Projects Plastics and Composite Materials: Forming and Shaping Introduction Extrusion Injection Molding Blow Molding Rotational Molding Thermoforming Compression Molding Transfer Molding Casting Foam Molding Cold Forming and Solid-phase Forming Processing Elastomers Processing Polymer-matrix Composites Processing Metal-matrix and Ceramic-matrix Composites Design Considerations Economics of Processing Plastics and Composite Materials 530 Summary 531 Key Terms 531 Bibliography 532 Review Questions 532 Qualitative Problems 532 Quantitative Problems 533 Synthesis, Design, and Projects 533 Rapid-prototyping Processes and Operations Introduction Subtractive Processes Additive Processes Virtual Prototyping Self-replicating Machines Direct Manufacturing and Rapid Tooling 553 Summary 560 Key Terms 560 Bibliography 560 Review Questions 561 Qualitative Problems 561 Quantitative Problems 562 Synthesis, Design, and Projects 562

10 Part IV: Machining Tools 563 Processes and Machine Fundamentals of Machining Introduction Mechanics of Cutting Cutting Forces and Power Temperatures in Cutting Tool Life: Wear and Failure Surface Finish and Integrity Machinability 591 Summary 595 Key Terms 596 Bibliography 596 Review Questions 596 Qualitative Problems 597 Quantitative Problems 598 Synthesis, Design, and Projects Cutting-tool Materials and Cutting Fluids Introduction High-speed Steels Cast-cobalt Alloys Carbides Coated Tools Alumina-based Ceramics Cubic Boron Nitride Silicon-nitride-based Ceramics Diamond Whisker-reinforced Materials and Nanomaterials Tool Costs and Reconditioning of Tools Cutting Fluids 616 Summary 622 Key Terms 622 Bibliography 622 Review Questions 623 Qualitative Problems 623 Quantitative Problems 624 Synthesis, Design, and Projects Machining Processes: Turning and Hole Making Introduction The Turning Process Lathes and Lathe Operations Boring and Boring Machines Drilling, Drills, and Drilling Machines 652

11 23.6 Reaming and Reamers Tapping and Taps 662 Summary 664 Key Terms 665 Bibliography 665 Review Questions 665 Qualitative Problems 666 Quantitative Problems 666 Synthesis, Design, and Projects Machining Processes: Milling, Broaching, Sawing, Filing, and Gear Manufacturing Introduction Milling and Milling Machines Planing and Shaping Broaching and Broaching 24.5 Sawing Filing 692 Machines Gear Manufacturing by Machining 692 Summary 699 Key Terms 700 Bibliography 700 Review Questions 700 Qualitative Problems 700 Quantitative Problems 701 Synthesis, Design, and Projects Machining Centers, Machine-tool Structures, and Machining Economics Introduction Machining Centers Machine-tool Structures Vibration and Chatter in Machining Operations High-speed Machining Hard Machining Ultraprecision Machining Machining Economics 722 Summary 726 Key Terms 726 Bibliography 727 Review Questions 727 Qualitative Problems 727 Quantitative Problems 728 Synthesis, Design, and Projects Abrasive Machining and Finishing Operations Introduction Abrasives and Bonded Abrasives The Grinding Process Grinding Operations and Machines Design Considerations for Grinding Ultrasonic Machining Finishing Operations 756

12 Contents xv 26.8 Deburring Operations Economics of Abrasive Machining and Finishing Operations 764 Summary 765 Key Terms 765 Bibliography 766 Review Questions 766 Qualitative Problems 767 Quantitative Problems 767 Synthesis, Design, and Projects 768 Advanced Machining Processes and Equipment Introduction Chemical Machining Electrochemical Machining Electrochemical Grinding Electrical-discharge Machining Laser-beam Machining Electron-beam Machining Water-jet Machining Abrasive-jet Machining Hybrid Machining Systems Economics of Advanced Machining Processes 791 Summary 794 Key Terms 794 Bibliography 795 Review Questions 795 Qualitative Problems 795 Quantitative Problems 796 Synthesis, Design, and Projects 796 PartV: Micromanufacturing and Fabrication of Microelectronic Devices Fabrication of Microelectronic Devices Introduction Clean Rooms Semiconductors and Silicon Crystal Growing and Wafer Preparation Film Deposition Oxidation Lithography Etching Diffusion and Ion Implantation Metallization and Testing Wire Bonding and Packaging Yield and Reliability Printed Circuit Boards 835 Summary 837 Key Terms 838 Bibliography 838 Review Questions 838 Qualitative Problems 839 Quantitative Problems 839 Synthesis, Design, and Projects 840

13 Fabrication of Microelectromechanical Devices and Systems; Nanoscale Manufacturing Introduction Micromachining of MEMS Devices Electroforming-based Processes Solid Free-form Fabrication of Devices Nanoscale Manufacturing 866 Summary 869 Key Terms 869 Bibliography 869 Review Questions 870 Qualitative Problems 870 Quantitative Problems 870 Synthesis, Design, and Projects 871 Part VI: Joining Processes and Equipment Fusion-welding Processes Introduction Oxyfuel-gas Welding Arc-welding Processes: Nonconsumable Electrode Arc-welding Processes: Consumable Electrode Electrodes for Arc Welding Electron-beam Welding Laser-beam Welding Cutting The Weld Joint, Weld Quality, and Testing Joint Design and Process Selection 905 Summary 908 Key Terms 909 Bibliography 909 Review Questions 909 Qualitative Problems 910 Quantitative Problems 910 Synthesis, Design, and Projects Solid-State Welding Processes Introduction Cold Welding and Roll Bonding Ultrasonic Welding Friction Welding Resistance Welding Explosion Welding Diffusion Bonding Economics of Welding Operations 928 Summary 930 Key Terms 930 Bibliography 931 Review Questions 931 Qualitative Problems 931 Quantitative Problems 932 Synthesis, Design, and Projects 932

14 Brazing, Soldering, Adhesive-bonding, and Mechanical Fastening Processes Introduction Brazing Soldering Adhesive-bonding Mechanical Fastening Joining Plastics, Ceramics, and Glasses Economics of Joining Operations 957 Summary 958 Key Terms 958 Bibliography 959 Review Questions 959 Qualitative Problems 959 Quantitative Problems 960 Synthesis, Design, and Projects 960 Part VII: Surface Technology Surface Roughness and Measurement; Friction, Wear, and Lubrication Introduction Surface Structure and Integrity Surface Texture and Roughness Friction Wear Lubrication Metalworking Fluids and Their Selection 978 Summary 981 Key Terms 982 Bibliography 982 Review Questions 983 Qualitative Problems 983 Quantitative Problems 984 Synthesis, Design, and Projects Surface Treatments, Coatings, and Cleaning Introduction Mechanical Surface Treatments Mechanical Plating and Cladding Case Hardening and Hard Facing Thermal Spraying Vapor Deposition Ion Implantation and Diffusion Coating Laser Treatments Electroplating, Electroless Plating, and Electroforming Conversion Coatings Hot Dipping Porcelain Enameling; Ceramic and Organic Coatings 999

15 xviii Contents Diamond Coating and Diamond-like Carbon Surface Texturing Painting Cleaning of Surfaces 1002 Summary 1004 Key Terms 1004 Bibliography 1004 Review Questions 1005 Qualitative Problems 1005 Quantitative Problems 1005 Synthesis, Design, and Projects 1005 PartVIII: Engineering Metrology, Instrumentation, and Quality Assurance Engineering Metrology and Instrumentation Introduction Measurement Standards Geometric Features of Parts: Analog and Digital Measurements Traditional Measuring Methods and Instruments Modern Measuring Instruments and Machines Automated Measurement General Characteristics and Selection of Measuring Instruments Geometric Dimensioning and Tolerancing 1021 Summary 1027 Key Terms 1027 Bibliography 1027 Review Questions 1028 Qualitative Problems 1028 Quantitative Problems 1029 Synthesis, Design, and Projects Quality Assurance, Testing, and Inspection Introduction Product Quality Quality Assurance Total Quality Management Taguchi Methods The ISO and QS Standards Statistical Methods of Quality Control Statistical Process Control Reliability of Products and Processes Nondestructive Testing Destructive Testing Automated Inspection 1052

16 Contents xix Summary 1053 Key Terms 1054 Bibliography 1054 Review Questions 1054 Qualitative Problems 1055 Quantitative Problems 1055 Synthesis, Design, and Projects 1056 Part IX: Manufacturing in a Competitive Environment ^ Automation of Manufacturing Processes and Operations Introduction Automation Numerical Control Adaptive Control Material Handling and Movement Industrial Robots Sensor Technology Flexible Fixturing Assembly Systems Design Considerations for Fixturing, Assembly, Disassembly, and Servicing Economic Considerations 1096 Summary 1097 Key Terms 1098 Bibliography 1098 Review Questions 1098 Qualitative Problems 1099 Quantitative Problems 1099 Synthesis, Design, and Projects Computer-aided Manufacturing Introduction Manufacturing Systems Computer-integrated Manufacturing Computer-aided Design and Engineering Computer-aided Manufacturing Computer-aided Process Planning Computer Simulation of Manufacturing Processes and Systems Group Technology 1114 Summary 1122 Key Terms 1122 Bibliography 1122 Review Questions 1123 Qualitative Problems 1123 Synthesis, Design, and Projects Computer-integrated Manufacturing Systems Introduction Cellular Manufacturing 1125

17 39.3 Flexible Manufacturing Systems Holonic Manufacturing Just-in-time Production Lean Manufacturing Communications Networks in Manufacturing Artificial Intelligence Economic Considerations 1138 Summary 1138 Key Terms 1139 Bibliography 1139 Review Questions 1139 Qualitative Problems 1140 Synthesis, Design, and Projects 1140 Product Design and Manufacturing in a Competitive Environment Introduction Product Design Product Quality Life-cycle Assessment and Sustainable Manufacturing Energy Consumption in Manufacturing Material Selection for Products Material Substitution Manufacturing Process Capabilities Process Selection Manufacturing Costs and Cost Reduction 1158 Summary 1162 Key Terms 1162 Bibliography 1162 Review Questions 1163 Qualitative Problems 1163 Synthesis, Design, and Projects 1164 Index 1167