Fundamentals od modern manufacturing : Materials, processes, and systems

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FEATURES OF THIS BOOK AND ITS WEBSITE

FOR STUDENTS:

Fundamentals of Modern Manufacturing: Materials, Processes, and Systems con￾tains 40 chapters. Chapter 1 provides an introduction and overview of manufactur￾ing. Chapters 2 through 9 are concerned with engineering materials and product

attributes; Chapters 10 through 36 cover manufacturing processes and related tech￾nologies; and Chapters 37 through 40 describe the systems of manufacturing.

To assist in the learning process for students, the following materials are provided

in the book:

➢ More than 550 end-of-chapter Problems. The answers to selected problems can

be found in an Appendix at the back of the book (before the Index).

➢ Many numerical example problems throughout the text. These example problems

are similar to some of the end-of-chapter exercise problems.

➢ More than 750 end-of-chapter Review Questions. These questions are descriptive

whereas nearly all of the end-of-chapter Problems are quantitative.

➢ Historical Notes describing the origins of many of the manufacturing topics

discussed in the book.

➢ Units used in the book (International System and U.S. Customary System) are

provided in the inside back cover, which also includes procedures for converting

between SI and USCS units.

In addition, we have provided the following materials on the companion website for

the book:

➢ Video clips of many of the manufacturing processes and related topics that are

described in the book.

➢ More than 600 Multiple Choice Quiz questions, one quiz for each chapter,

which can be used by students to test their knowledge of chapter topics. Stu￾dents should consult with their instructors about the availability of the correct

answers to these questions.

To access the website, go to www.wiley.com/college/groover. After entering the web￾site, students should select the link for this book and click on “student companion site”

to access the content for students.

FOR INSTRUCTORS:

For instructors who adopt the book for their courses, the following support materials

are available on the companion website for the book:

➢ A set of Powerpoint slides for all chapters for instructors to use in their class

lectures. Instructors can decide whether to make these slides available to their

students.

FCOVER.indd 1 7/18/12 2:05 PM

➢ A series of video clips of many of the processes discussed in the book. These

video clips can be used in class to illustrate the processes, and students can also

view these clips independently on the website.

➢ A Solutions Manual covering all review questions and end-of-chapter problems

in the book. Instructors can use these materials as homework exercises and/or

to design tests and exams for their courses.

➢ A set of multiple choice quizzes, one quiz for each chapter, with a separate folder

for instructors that includes answers to the quiz questions. Instructors can decide

whether to make the answers available to their students. Instructors can also use

the quiz questions to design tests and exams for their courses.

➢ A set of case studies developed by Prof. Dan Waldorf of California Polytechnic

University at San Luis Obispo. These case studies are designed to be used in

conjunction with the video clips located on the website as well as the book.

Instructors can use these materials as homework or laboratory exercises.

To access the website, go to www.wiley.com/college/groover. After entering the

website, instructors should select the link for this book and click on “instructor

companion site” to access the content for instructors.

FCOVER.indd 2 7/18/12 2:05 PM

Fundamentals

of Modern

Manufacturing

Materials, Processes, and Systems

Fifth Edition

Mikell P. Groover

Professor Emeritus of Industrial and

Systems Engineering Lehigh University

The author and publisher gratefully acknowledge the contributions

of Dr. Gregory L. Tonkay, Associate Professor of Industrial and Systems

Engineering, and Associate Dean, College of Engineering and

Applied Science, Lehigh University.

FFIRS.indd i 8/9/12 12:03 AM

VICE PRESIDENT AND EXECUTIVE PUBLISHER Don Fowley

ACQUISITION EDITOR Linda Ratts

SENIOR CONTENT MANAGER Lucille Buonocore

SENIOR PRODUCTION EDITOR Anna Melhorn

SENIOR DESIGNER Jim O’Shea

EDITORIAL ASSISTANT Christopher Teja

MARKETING MANAGER Christopher Ruel

CREATIVE DIRECTOR Harry Nolan

PRODUCTION SERVICES Suzanne Ingrao/Ingrao Associates

FRONT COVER PHOTO Courtesy of Kennametal, Inc.

This book was set in Times Roman by Thomson Digital, and printed and bound by Quad Graphics/Versailles.

This book is printed on acid-free paper. ∞

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978-1-118-231463

Printed in the United States of America

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iii

PREFACE

Fundamentals of Modern Manufacturing: Materials, Processes, and Systems is

designed for a fi rst course or two-course sequence in manufacturing at the junior

level in mechanical, industrial, and manufacturing engineering curricula. Given

its coverage of engineering materials, it may also be suitable for materials science

and engineering courses that emphasize materials processing. Finally, it may be

appropriate for technology programs related to the preceding engineering dis￾ciplines. Most of the book’s content is concerned with manufacturing processes

(about 65% of the text), but it also provides signifi cant coverage of engineering

materials and production systems. Materials, processes, and systems are the basic

building blocks of modern manufacturing and the three broad subject areas cov￾ered in the book.

APPROACH

The author’s objective in this and the preceding editions is to provide a treatment of

manufacturing that is modern and quantitative. Its claim to be “modern” is based on

(1) its balanced coverage of the basic engineering materials (metals, ceramics, poly￾mers, and composite materials), (2) its inclusion of recently developed manufactur￾ing processes in addition to the traditional processes that have been used and refi ned

over many years, and (3) its comprehensive coverage of electronics manufacturing

technologies. Competing textbooks tend to emphasize metals and their processing at

the expense of the other engineering materials, whose applications and methods of

processing have grown signifi cantly in the last several decades. Also, most competing

books provide minimum coverage of electronics manufacturing. Yet the commercial

importance of electronics products and their associated industries have increased

substantially during recent decades.

The book’s claim to be more “quantitative” is based on its emphasis on manu￾facturing science and its greater use of mathematical models and quantitative

(end-of-chapter) problems than other manufacturing textbooks. In the case of

some processes, it was the fi rst book on manufacturing processes to provide a

quantitative engineering coverage of the topic.

ORGANIZATION OF THE BOOK

The fi rst chapter provides an introduction and overview of manufacturing. Manu￾facturing is defi ned, and the materials, processes, and systems of manufacturing are

briefl y described. New to this edition is a section on manufacturing economics. The

chapter concludes with a list of developments that have affected manufacturing over

the past 50 or so years.

The remaining 39 chapters are organized into 11 parts. Part I, titled Material

Properties and Product Attributes, consists of four chapters that describe the impor￾tant characteristics of materials and the products made from them. Part II discusses

the four basic engineering materials: metals, ceramics, polymers, and composites.

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iv Preface

Part III begins the coverage of the part-shaping processes, which are organized

into four categories: (1) solidifi cation processes, (2) particulate processes, (3) defor￾mation processes, and (4) material removal processes. Part III consists of six chap￾ters on the solidifi cation processes that include casting of metals, glassworking, and

polymer shaping. In Part IV, the processing of powders of metals and ceramics is

covered in two chapters. Part V deals with metal deformation processes such as roll￾ing, forging, extrusion, and sheet metalworking. Finally, Part VI discusses the material

removal processes. Four chapters are devoted to machining, and two chapters cover

grinding (and related abrasive processes) and the nontraditional material removal

technologies.

Part VII consists of two chapters on other types of processing operations: property

enhancing processes and surface processing. Property enhancing is accomplished by

heat treatment, and surface processing includes operations such as cleaning, electro￾plating, vapor deposition processes, and coating (painting).

Joining and assembly processes are considered in Part VIII, which is organized

into four chapters on welding, brazing, soldering, adhesive bonding, and mechanical

assembly.

Several unique processes that do not neatly fi t into the preceding classifi cation

scheme are covered in Part IX, titled Special Processing and Assembly Technologies.

Its fi ve chapters cover rapid prototyping and additive manufacturing, processing of

integrated circuits, electronics assembly, microfabrication, and nano fabrication.

Part X begins the coverage of the systems of manufacturing. Its two chapters

deal with the types of automation technologies in a factory, such as numerical

control and industrial robotics, and how these technologies are integrated into

systems, such as production lines, manufacturing cells, and fl exible manufactur￾ing systems. Finally, Part XI deals with manufacturing support systems: process

planning, production planning and control, lean production, and quality control

and inspection.

NEW TO THIS EDITION

This fi fth edition builds on the fourth edition. The content has been increased and

this is refl ected in the page count. In previous editions, the author has attempted to

keep the page count at around 1000. The fi fth edition contains about 1100 pages.

Additions and changes in the fi fth edition include the following:

➢ The chapter count has been reduced from 42 to 40 through consolidation of

several chapters. The two chapters in the fourth edition on rubber processing

(Chapter 14) and polymer matrix composites processing (Chapter 15) have

been combined into a single chapter, and the two chapters in the fourth edi￾tion on process planning (Chapter 40) and production planning and control

(Chapter 41) have been combined into one chapter.

➢ In Chapter 1, two new sections have been added on manufacturing econom￾ics (cycle time and cost analysis) and recent developments that have affected

manufacturing.

➢ Troubleshooting guides have been added to several of the machining chapters.

➢ The chapter on rapid prototyping has been extensively revised, and a new sec￾tion on cycle time and cost analysis has been added. The chapter title has been

FPREF.indd iv 7/18/12 12:18 PM

Preface v

changed to Rapid Prototyping and Additive Manufacturing to refl ect the evolu￾tion of the RP technologies.

➢ The chapter on integrated circuit processing has been updated. The coverage of

Rent’s rule has been expanded to include how the rule can be applied to several

different types of integrated circuits.

➢ The chapter on electronics packaging has been reorganized, with more empha￾sis on surface mount technology.

➢ A new section on the classifi cation of nanotechnology products has been added

to the chapter on nanofabrication.

➢ A section on mass customization has been added in the chapter on integrated

manufacturing systems.

➢ A section on lean production and the Toyota production system has been added

to the chapter on process planning and production control.

➢ New historical notes have been added on metrology, rapid prototyping, and lean

production.

➢ The number of example problems imbedded in the text has been increased from

47 in the fourth edition to 65 in the fi fth. Included are new example problems

on manufacturing economics, tensile testing, machining time, rapid prototyping

costs, and integrated circuit processing.

➢ More than 60% of the end-of-chapter problems are new or revised, and the

total number of end-of-chapter problems has been increased. End-of-chapter

problems have been labeled as using either SI or USCS units, so if instructors

want to assign problems with only one type of units, this will help them identify

the problems that are of the desired type. Answers to selected end-of-chapter

problems are provided in an appendix at the back of the book.

➢ The multiple choice quizzes that were included at the end of each chapter in the

fourth edition are now available on the website for the book. The total number

of multiple choice questions has been increased from 495 in the fourth edition

to 745 for the fi fth edition.

➢ The DVD that was included with the fourth edition has now been made avail￾able as a collection of video clips on the website for the book.

SUPPORT MATERIAL FOR INSTRUCTORS

For instructors who adopt the book for their courses, the following support materials

are available on the website for the book:

➢ A complete set of Powerpoint slides for all chapters is available to instructors

for their class lectures. Instructors can decide whether to make these slides

available to their students.

➢ A series of video clips of many of the processes discussed in the book are avail￾able on the website for the book. These can be used in class to illustrate the

processes, and students can also view these clips independently on the website.

➢ A Solutions Manual (in digital format) covering all review questions and end￾of-chapter problems is available on the website for the book. Instructors can use

these materials as homework exercises or to make up quizzes for their courses.

FPREF.indd v 7/18/12 12:18 PM

vi Preface

➢ An extensive set of multiple choice quizzes (with a separate folder that includes

answers to the quiz questions) is available for instructors to provide to their

students as individual learning exercises or to make up quizzes for their courses.

➢ A set of case studies developed by Prof. Dan Waldorf of California Polytechnic

University is available on the website for the book. These case studies are designed

to be used in conjunction with the video clips located on the website. Instructors

can use these materials as homework or laboratory exercises.

These support materials may be found at the website www.wiley.com/college/groover.

Evidence that the book has been adopted as the main textbook for the course must be

verifi ed. Individual questions or comments may be directed to the author personally

at [email protected].

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vii

ACKNOWLEDGMENTS

I would like to express my appreciation to the following people who served as

technical reviewers of individual sets of chapters for the fi rst edition: Iftikhar

Ahmad (George Mason University), J. T. Black (Auburn University), David Bourell

(University of Texas at Austin), Paul Cotnoir (Worcester Polytechnic Institute),

Robert E. Eppich (American Foundryman’s Society), Osama Eyeda (Virginia

Polytechnic Institute and State University), Wolter Fabricky (Virginia Polytechnic

Institute and State University), Keith Gardiner (Lehigh University), R. Heikes

(Georgia Institute of Technology), Jay R. Geddes (San Jose State University),

Ralph Jaccodine (Lehigh University), Steven Liang (Georgia Institute of Technol￾ogy), Harlan MacDowell (Michigan State University), Joe Mize (Oklahoma State

University), Colin Moodie (Purdue University), Michael Philpott (University of

Illinois at Champaign-Urbana), Corrado Poli (University of Massachusetts at

Amherst), Chell Roberts (Arizona State University), Anil Saigal (Tufts University),

G. Sathyanarayanan (Lehigh University), Malur Srinivasan (Texas A&M

University), A. Brent Strong (Brigham Young University), Yonglai Tian (George

Mason University), Gregory L. Tonkay (Lehigh University), Chester VanTyne

(Colorado School of Mines), Robert Voigt (Pennsylvania State University), and

Charles White (GMI Engineering and Management Institute).

For their reviews of certain chapters in the second edition, I would like to thank

John T. Berry (Mississippi State University), Rajiv Shivpuri (Ohio State University),

James B. Taylor (North Carolina State University), Joel Troxler (Montana State

University), and Ampere A. Tseng (Arizona State University).

For their advice and encouragement on the third edition, I would like to thank

several of my colleagues at Lehigh, including John Coulter, Keith Gardiner, Andrew

Herzing, Wojciech Misiolek, Nicholas Odrey, Gregory Tonkay, and Marvin White. I

am especially grateful to Andrew Herzing in the Materials Science and Engineer￾ing Department at Lehigh for his review of the new nanofabrication chapter and to

Greg Tonkay in my own department for developing many of the new and revised

problems and questions in this new edition. Of the many great end-of-chapter prob￾lems that he contributed, I would single out Problem 33.19 (in this fi fth edition) as

truly a world-class homework problem.

For their advice on the fourth edition, I would like to thank the following peo￾ple: Barbara Mizdail (The Pennsylvania State University – Berks campus) and

Jack Feng (formerly of Bradley University and now at Caterpillar, Inc.) for con￾veying questions and feedback from their students, Larry Smith (St. Clair College,

Windsor, Ontario) for his advice on using the ASME standards for hole drilling,

Richard Budihas (Voltaic LLC) for his contributed research on nanotechnology

and integrated circuit processing, and colleague Marvin White at Lehigh for his

insights on integrated circuit technology.

For their reviews of the fourth edition that were incorporated into this fi fth edi￾tion, I would like to thank the following people: Gayle Ermer (Calvin College),

Shivan Haran (Arkansas State University), Yong Huang (Clemson University),

Marian Kennedy (Clemson University), Aram Khachatourians (California State

University, Northridge), Amy Moll, (Boise State University), Victor Okhuysen

(California State Polytechnic University, Pomona), Ampere Tseng (Arizona State

FACK.indd vii 7/18/12 1:20 PM

viii Acknowledgments

University), Daniel Waldorf (California State Polytechnic University, San Luis

Obispo), and Parviz Yavari (California State University, Long Beach). I would also

like to thank Dan Waldorf for developing the set of case studies that are available

on the website for the book.

In addition, I want to acknowledge my colleagues at Wiley: Executive Editor

Linda Ratts, Editorial Assistant Christopher Teja, and Production Editors Anna

Melborn and Suzanne Ingrao (of Ingrao Associates) for their advice and efforts

on behalf of the book. And fi nally, I want to acknowledge several of my colleagues

at Lehigh for their contributions to the fi fth edition: David Angstadt of Lehigh’s

Department of Mechanical Engineering and Mechanics; Ed Force II, Laboratory

Technician in our George E. Kane Manufacturing Technology Laboratory; and

Marcia Groover, my wife and colleague at the University. I sometimes write text￾books about how computers are used in manufacturing, but when my computer

needs fi xing, she is the one I call on.

FACK.indd viii 7/18/12 1:20 PM

ix

ABOUT THE AUTHOR

Mikell P. Groover is Professor Emeritus of Industrial and Systems Engineering at

Lehigh University. He received his B.A. in Arts and Science (1961), B.S. in Mechanical

Engineering (1962), M.S. in Industrial Engineering (1966), and Ph.D. (1969), all from

Lehigh. He is a Registered Professional Engineer in Pennsylvania. His industrial

experience includes several years as a manufacturing engineer with Eastman Kodak

Company. Since joining Lehigh, he has done consulting, research, and project work

for a number of industrial companies.

His teaching and research areas include manufacturing processes, production sys￾tems, automation, material handling, facilities planning, and work systems. He has

received a number of teaching awards at Lehigh University, as well as the Albert G.

Holzman Outstanding Educator Award from the Institute of Industrial Engineers

(1995) and the SME Education Award from the Society of Manufacturing Engineers

(2001). His publications include over 75 technical articles and twelve books (listed

below). His books are used throughout the world and have been translated into

French, German, Spanish, Portuguese, Russian, Japanese, Korean, and Chinese. The

fi rst edition of the current book Fundamentals of Modern Manufacturing received

the IIE Joint Publishers Award (1996) and the M. Eugene Merchant Manufacturing

Textbook Award from the Society of Manufacturing Engineers (1996). Dr. Groover

is a Fellow of the Institute of Industrial Engineers (1987) and the Society of Manufac￾turing Engineers (1996).

PREVIOUS BOOKS BY THE AUTHOR

Automation, Production Systems, and Computer-Aided Manufacturing, Prentice

Hall, 1980.

CAD/CAM: Computer-Aided Design and Manufacturing, Prentice Hall, 1984

(co-authored with E. W. Zimmers, Jr.).

Industrial Robotics: Technology, Programming, and Applications, McGraw-Hill

Book Company, 1986 (co-authored with M. Weiss, R. Nagel, and N. Odrey).

Automation, Production Systems, and Computer Integrated Manufacturing, Prentice

Hall, 1987.

Fundamentals of Modern Manufacturing: Materials, Processes, and Systems, origi￾nally published by Prentice Hall in 1996, and subsequently published by John

Wiley & Sons, Inc., 1999.

Automation, Production Systems, and Computer Integrated Manufacturing, Second

Edition, Prentice Hall, 2001.

Fundamentals of Modern Manufacturing: Materials, Processes, and Systems, Second

Edition, John Wiley & Sons, Inc., 2002.

Work Systems and the Methods, Measurement, and Management of Work, Pearson

Prentice Hall, 2007.

FLAST.indd ix 7/18/12 11:46 AM

x About the Author

Fundamentals of Modern Manufacturing: Materials, Processes, and Systems, Third

Edition, John Wiley & Sons, Inc., 2007.

Automation, Production Systems, and Computer Integrated Manufacturing, Third

Edition, Pearson Prentice Hall, 2008.

Fundamentals of Modern Manufacturing: Materials, Processes, and Systems, Fourth

Edition, John Wiley & Sons, Inc., 2010.

Introduction to Manufacturing Processes, John Wiley & Sons, Inc., 2012.

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xi

CONTENTS

1 INTRODUCTION AND OVERVIEW

OF MANUFACTURING 1

1.1 What Is Manufacturing? 2

1.2 Materials in Manufacturing 9

1.3 Manufacturing Processes 11

1.4 Production Systems 18

1.5 Manufacturing Economics 22

1.6 Recent Developments in Manufacturing 27

Part I Material Properties and Product

Attributes 36

2 THE NATURE OF MATERIALS 36

2.1 Atomic Structure and the Elements 37

2.2 Bonding between Atoms and Molecules 39

2.3 Crystalline Structures 41

2.4 Noncrystalline (Amorphous) Structures 47

2.5 Engineering Materials 49

3 MECHANICAL PROPERTIES OF

MATERIALS 52

3.1 Stress–Strain Relationships 52

3.2 Hardness 67

3.3 Effect of Temperature on Properties 71

3.4 Fluid Properties 73

3.5 Viscoelastic Behavior of Polymers 76

4 PHYSICAL PROPERTIES OF MATERIALS 83

4.1 Volumetric and Melting Properties 83

4.2 Thermal Properties 86

4.3 Mass Diffusion 88

4.4 Electrical Properties 90

4.5 Electrochemical Processes 92

5 DIMENSIONS, SURFACES, AND THEIR

MEASUREMENT 95

5.1 Dimensions, Tolerances, and Related

Attributes 96

5.2 Measuring Instruments and Gages 97

5.3 Surfaces 106

5.4 Measurement of Surfaces 112

5.5 Effect of Manufacturing Processes 114

Part II Engineering Materials 118

6 METALS 118

6.1 Alloys and Phase Diagrams 119

6.2 Ferrous Metals 124

6.3 Nonferrous Metals 142

6.4 Superalloys 155

7 CERAMICS 159

7.1 Structure and Properties of

Ceramics 160

7.2 Traditional Ceramics 163

7.3 New Ceramics 165

7.4 Glass 168

7.5 Some Important Elements Related to

Ceramics 172

8 POLYMERS 176

8.1 Fundamentals of Polymer Science and

Technology 178

8.2 Thermoplastic Polymers 189

8.3 Thermosetting Polymers 196

8.4 Elastomers 200

8.5 Polymer Recycling and

Biodegradability 208

9 COMPOSITE MATERIALS 212

9.1 Technology and Classifi cation of

Composite Materials 213

9.2 Metal Matrix Composites 222

9.3 Ceramic Matrix Composites 224

9.4 Polymer Matrix Composites 225

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