Manufacturing engineering and technology

MANUFACTURING ENGINEERING AND TECHNOLOGY

SEVENTH EDITION IN SI UNITS

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Manufacturing

Engineering

and Technology

SEVENTH

EDITION

IN SI UNITS

Serope Kalpakjian

Illinois Institute of Technology

Steven R. Schmid

The University of Notre Dame

SI E dition C ontributions 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

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Authorized adaptation from the United States edition, entitled Manufacturing Engineering and Technology, Seventh Edition,

ISBN: 9780133128741 by KALPAKJIAN, SEROPE; SCHMID, STEVEN, published by Pearson Education, Inc, Copyright

© 2014 Pearson Education, Inc.

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Printed in Singapore

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ISBN 978-981-06-9406-7

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To the memory of

Margaret Jean Kalpakjian

“And ever has it been known that love knows not its own depth

until the hour o f separation.”

Khalil Gibran

Contents

Preface xxiii

About the Authors xxvii

General Introduction 1

I.1 What is Manufacturing? 1

I.2 Product Design and Concurrent Engineering 6

I.3 Design for Manufacture, Assembly, Disassembly, and Service 10

I.4 Green Design and Manufacturing 11

I.5 Selection of Materials 13

I.6 Selection of Manufacturing Processes 16

I.7 Computer-integrated Manufacturing 25

I.8 Quality Assurance and Total Quality Management 28

I.9 Lean Production and Agile Manufacturing 30

I.10 Manufacturing Costs and Global Competition 31

I.11 Trends in Manufacturing 32

Part I: Fundamentals of Materials: Behavior

and Manufacturing Properties 35

1 The Structure of Metals 38

1.1 Introduction 38

1.2 Types of Atomic Bonds 39

1.3 The Crystal Structure of Metals 40

1.4 Deformation and Strength of Single Crystals 42

1.5 Grains and Grain Boundaries 45

1.6 Plastic Deformation of Polycrystalline Metals 48

1.7 Recovery, Recrystallization, and Grain Growth 49

1.8 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

2 Mechanical Behavior, Testing, and Manufacturing

Properties of Materials 55

2.1 Introduction 55

2.2 Tension 56

2.3 Compression 65

2.4 Torsion 66

2.5 Bending (Flexure) 67

2.6 Hardness 67

2.7 Fatigue 73

2.8 Creep 74

2.9 Impact 74

2.10 Failure and Fracture of Materials 75

2.11 Residual Stresses 80

2.12 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

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 98 Bibliography 98

Review Questions 98 Qualitative Problems 98

Quantitative Problems 99 Synthesis, Design, and Projects 99

4 Metal Alloys: Their Structure and Strengthening

by Heat Treatment 101

4.1 Introduction 101

4.2 Structure of Alloys 102

4.3 Phase Diagrams 104

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 109

4.7 Heat Treatment of Ferrous Alloys 111

4.8 Hardenability of Ferrous Alloys 113

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 124

Summary 125 Key Terms 126 Bibliography 126

Review Questions 126 Qualitative Problems 127

Quantitative Problems 127 Synthesis, Design, and Projects 127

5 Ferrous Metals and Alloys: Production, General

Properties, and Applications 128

5.1 Introduction 128

5.2 Production of Iron and Steel 129

5.3 Casting of Ingots 132

5.4 Continuous Casting 133

5.5 Carbon and Alloy Steels 135

5.6 Stainless Steels 142

5.7 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

6 Nonferrous Metals and Alloys: Production,

General Properties, and Applications 150

6.1 Introduction 150

6.2 Aluminum and Aluminum Alloys 151

6.3 Magnesium and Magnesium Alloys 155

6.4 Copper and Copper Alloys 156

6.5 Nickel and Nickel Alloys 158

6.6 Superalloys 159

6.7 Titanium and Titanium Alloys 160

6.8 Refractory Metals and Alloys 161

6.9 Beryllium 162

6.10 Zirconium 162

6.11 Low-melting Alloys 162

6.12 Precious Metals 164

6.13 Shape-memory Alloys (Smart Materials) 164

6.14 Amorphous Alloys (Metallic Glasses) 165

6.15 Metal Foams 165

Summary 166 Key Terms 166 Bibliography 166

Review Questions 167 Qualitative Problems 167

Quantitative Problems 167 Synthesis, Design, and Projects 168

7 Polymers: Structure, General Properties,

and Applications 169

7.1 Introduction 169

7.2 The Structure of Polymers 171

7.3 Thermoplastics 178

7.4 Thermosetting Plastics 181

7.5 Additives in Plastics 182

7.6 General Properties and Applications

of Thermoplastics 183

7.7 General Properties and Applications

of Thermosetting Plastics 186

7.8 Biodegradable Plastics 187

7.9 Elastomers (Rubbers) 188

Summary 189 Key Terms 190 Bibliography 190

Review Questions 191 Qualitative Problems 191

Quantitative Problems 192 Synthesis, Design, and Projects 193

8 Ceramics, Glass, Graphite, Diamond, and

Nanomaterials: Structure, General Properties,

and Applications 194

8.1 Introduction 194

8.2 The Structure of Ceramics 195

8.3 General Properties and Applications

of Ceramics 200

8.4 Glasses 204

8.5 Glass Ceramics 206

8.6 Graphite 207

8.7 Diamond 209

8.8 Nanomaterials 210

Summary 211 Key Terms 212 Bibliography 212

Review Questions 212 Qualitative Problems 213

Quantitative Problems 213 Synthesis, Design, and Projects 213

9 Composite Materials: Structure, General

Properties, and Applications 215

9.1 Introduction 215

9.2 The Structure of Reinforced Plastics 216

9.3 Properties of Reinforced Plastics 221

9.4 Applications of Reinforced Plastics 224

9.5 Metal-matrix Composites 226

9.6 Ceramic-matrix Composites 228

9.7 Other Composites 229

Summary 230 Key Terms 230 Bibliography 230

Review Questions 231 Qualitative Problems 231

Quantitative Problems 232 Synthesis, Design, and Projects 232

Part II: M etal-casting Processes

and Equipment 235

10 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 246

10.5 Heat Transfer 247

10.6 Defects 249

Summary 252 Key Terms 252 Bibliography 253

Review Questions 253 Qualitative Problems 253

Quantitative Problems 254 Synthesis, Design, and Projects 255

1 1 Metal-casting Processes and Equipment 256

11.1 Introduction 256

11.2 Expendable-mold, Permanent-pattern Casting

Processes 260

11.3 Expendable-mold, Expendable-pattern Casting

Processes 269

11.4 Permanent-mold Casting Processes 276

11.5 Casting Techniques for Single-crystal Components 284

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 290 Qualitative Problems 291

Quantitative Problems 291 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 303

12.4 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

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 323

13.4 Rolling Mills 326

13.5 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 336

14 Metal-forging Processes and Equipment 337

14.1 Introduction 337

14.2 Open-die Forging 339

14.3 Impression-die and Closed-die Forging 342

14.4 Various Forging Operations 345

14.5 Forgeability of Metals; Forging Defects 349

14.6 Die Design, Die Materials, and Lubrication 351

14.7 Die-manufacturing Methods and Die Failure 354

14.8 Forging Machines 355

14.9 Economics of Forging 358

Summary 360 Key Terms 361 Bibliography 361

Review Questions 362 Qualitative Problems 362

Quantitative Problems 362 Synthesis, Design, and Projects 363

15 Metal Extrusion and Drawing Processes

and Equipment 364

15.1 Introduction 364

15.2 The Extrusion Process 366

15.3 Hot Extrusion 368

15.4 Cold Extrusion 372

15.5 Extrusion Defects 374

15.6 Design Considerations 376

15.7 Extrusion Equipment 376

15.8 The Drawing Process 377

15.9 Drawing Practice 379

15.10 Drawing Defects and Residual Stresses 382

15.11 Drawing Equipment 382

Summary 383 Key Terms 384 Bibliography 384

Review Questions 384 Qualitative Problems 384

Quantitative Problems 385 Synthesis, Design, and Projects 385

16 Sheet-metal Forming Processes

and Equipment 386

16.1 Introduction 386

16.2 Shearing 387

16.3 Sheet-metal Characteristics and Formability 397

16.4 Formability Tests for Sheet Metals 399

16.5 Bending Sheets, Plates, and Tubes 402

16.6 Miscellaneous Bending and Related Forming Operations 406

16.7 Deep Drawing 411

16.8 Rubber Forming and Hydroforming 419

16.9 Spinning 423

16.10 Superplastic Forming 426

16.11 Hot Stamping 427

16.12 Specialized Forming Processes 428

16.13 Manufacturing of Metal Honeycomb Structures 433

16.14 Design Considerations in Sheet-metal Forming 434

16.15 Equipment for Sheet-metal Forming 437

16.16 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

1 7 Powder Metal Processes and Equipment 444

17.1 Introduction 444

17.2 Production of Metal Powders 445

17.3 Compaction of Metal Powders 450

17.4 Sintering 461

17.5 Secondary and Finishing Operations 464

17.6 Design Considerations 466

17.7 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

18 Ceramics, Glasses, and Superconductors:

Processing and Equipment 475

18.1 Introduction 475

18.2 Shaping Ceramics 476

18.3 Forming and Shaping of Glass 483

18.4 Techniques for Strengthening and Annealing Glass 486

18.5 Design Considerations for Ceramics and Glasses 489

18.6 Processing of Superconductors 489