Materials and processes in manufacturing

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Yazar:

DeGarmo, E. Paul

ISBN:

9780471366799

Ek Yazar:

DeGarmo, E. Paul

Basım Bilgisi:

8th ed.

Yayın Bilgisi:

New York : John Wiley & Sons , 1999.

Fiziksel Tanım:

1259 s. ; 25 sm.

Özet:

Materials and Processes in Manufacturing -E. Paul Degarmo- 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 Chapters 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 Anisotropie 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 Chapters 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 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 Alloy s 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 Port 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 Parts 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) v 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 Port 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 Port 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 .>o, 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 < o 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 .

-o 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 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 Port 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 v 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 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 Port 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 o.’o 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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Library	Materyal Türü	Barkod	Yer Numarası	Durumu/İade Tarihi
Arıyor... Ferit Melen Library	Book	049674	670.42 DEGm 1999 k.1	Arıyor... Unknown

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