Materials and processes in manufacturing

FPREF 02/08/2012 14:29:45 Page 8

FFIRS 02/08/2012 14:25:43 Page 1

DeGarmo’s

MATERIALS

AND PROCESSES

IN MANUFACTURING

INTERNATIONAL STUDENT VERSION

ELEVENTH EDITION

J T. Black

Auburn University-Emeritus

Ronald A. Kohser

Missouri University of Science & Technology

John Wiley & Sons, Inc.

FFIRS 02/08/2012 14:25:43 Page 2

Copyright # 2013 John Wiley & Sons Singapore Pte. Ltd.

Cover image from # Benis Arapovic/Shutterstock

Founded in 1807, John Wiley & Sons, Inc. has been a valued source of knowledge and understanding for more than 200 years, helping people around

the world meet their needs and fulfill their aspirations. Our company is built on a foundation of principles that include responsibility to the

communities we serve and where we live and work. In 2008, we launched a Corporate Citizenship Initiative, a global effort to address the

environmental, social, economic, and ethical challenges we face in our business. Among the issues we are addressing are carbon impact, paper

specifications and procurement, ethical conduct within our business and among our vendors, and community and charitable support. For more

information, please visit our website: www.wiley.com/go/citizenship.

All rights reserved. This book is authorized for sale in Europe, Asia, Africa and the Middle East only and may not be exported outside of these

territories. Exportation from or importation of this book to another region without the Publisher’s authorization is illegal and is a violation of the

Publisher’s rights. The Publisher may take legal action to enforce its rights. The Publisher may recover damages and costs, including but not limited to

lost profits and attorney’s fees, in the event legal action is required.

No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical,

photocopying, recording, scanning, or otherwise, except as permitted under Section 107 or 108 of the 1976 United States Copyright Act, without either

the prior written permission of the Publisher or authorization through payment of the appropriate per-copy fee to the Copyright Clearance Center,

Inc., 222 Rosewood Drive, Danvers, MA 01923, website www.copyright.com. Requests to the Publisher for permission should be addressed to the

Permissions Department, John Wiley & Sons, Inc., 111 River Street, Hoboken, NJ 07030, (201) 748-6011, fax (201) 748-6008, website http://www.wiley

.com/go/permissions.

ISBN: 978-0-470-87375-5

Printed in Asia

10 9 8 7 6 5 4 3 2 1

FPREF 02/08/2012 14:29:44 Page 3

PREFACE

It’s a world of manufactured goods. Whether we like it or not, we all live in a technologi￾cal society. Every day we come in contact with hundreds of manufactured items, made

from every possible material. From the bedroom to the kitchen, to the workplace, we

use appliances, phones, cars, trains, and planes, TVs, cell phones, VCRs, DVD’s, furni￾ture, clothing, sports equipment, books and more! These goods are manufactured in

factories all over the world using manufacturing processes.

Basically, manufacturing is a value-adding activity, where the conversion of mate￾rials into products adds value to the original material. Thus, the objective of a company

engaged in manufacturing is to add value and to do so in the most efficient manner, with

the least amount of waste in terms of time, material, money, space, and labor. To mini￾mize waste and increase productivity, the processes and operations need to be properly

selected and arranged to permit smooth and controlled flow of material through the

factory and provide for product variety. Meeting these goals requires an engineer who

can design and operate an efficient manufacturing system. Here are the trends that are

impacting the manufacturing world.

Manufacturing is a global activity

Manufacturing is a global activity with companies sending work to other countr￾ies (China, Taiwan, Mexico) to take advantage of low-cost labor. Many US compa￾nies have plants in other countries and foreign companies have built plants in the

United States, to be nearer their marketplace. Automobile manufacturers from all

around the globe and their suppliers use just about every process described in this

book and some that we do not describe, often because they are closely held secrets.

It’s a digital world

Information technology and computers are growing exponentially, doubling in

power every year. Every manufacturing company has ready access to world-wide dig￾ital technology. Products can be built by suppliers anywhere in the world working

using a common set of digital information. Designs can be emailed to manufacturers

who can rapidly produce a prototype in metal or plastic in a day.

Lean manufacturing is widely practiced

Most (over 60%) manufacturing companies have restructured their facto￾ries (their manufacturing systems) to become lean producers, making goods of

superior quality, cheaper, faster in a flexible way (i.e., they are more responsive

to the customers). Almost every plant is doing something to make itself leaner.

Many of them have adopted some version of the Toyota Production System.

More importantly, these manufacturing factories are designed with the internal

customer (the workforce) in mind, so things like ergonomics and safety are key

design requirements. So while this book is all about materials and processes for

making the products, the design of the factory cannot be ignored when it comes

to making the external customer happy with the product and the internal cus￾tomer satisfied with the employer.

New products and materials need new processes

The number and variety of products and the materials from which they are

made continues to proliferate, while production quantities (lot sizes) have become

smaller. Existing processes must be modified to be more flexible, and new processes

must be developed.

Customers expect great quality

Consumers want better quality and reliability, so the methods, processes, and

people responsible for the quality must be continually improved. The trend toward

(improving) zero defects and continuous improvement requires continual changes to

the manufacturing system.

iii

FPREF 02/08/2012 14:29:44 Page 4

Rapid product development is required

Finally, the effort to reduce the time-to-market for new products is continuing.

Many companies are taking wholistic or system wide perspectives, including concur￾rent engineering efforts to bring product design and manufacturing closer to the cus￾tomer. There are two key aspects here. First, products are designed to be easier to

manufacture and assemble (called design for manufacture/assembly). Second, the

manufacturing system design is flexible (able to rapidly assimilate new products), so

the company can be competitive in the global marketplace.

& HISTORY OF THE TEXT

E. Paul DeGarmo was a mechanical engineering professor at the University of Califor￾nia, Berkley when he wrote the first edition of Materials and Processes in Manufactur￾ing, published by Macmillan in 1957. The book quickly became the emulated standard

for introductory texts in manufacturing. Second, third, and fourth editions followed in

1962, 1969, and 1974. DeGarmo had begun teaching at Berkeley in 1937, after earning

his M.S. in mechanical engineering from California Institute of Technology. DeGarmo

was a founder of the Department of Industrial Engineering (now Industrial Engineer￾ing and Operations Research) and served as its chair from 1956–1960. He was also

assistant dean of the College of Engineering for three years while continuing his teach￾ing responsibilities.

Dr. DeGarmo observed that engineering education had begun to place more

emphasis on the underlying sciences at the expense of hands on experience. Most of his

students were coming to college with little familiarity with materials, machine tools, and

manufacturing methods that their predecessors had acquired through the old ‘‘shop’’

classes. If these engineers and technicians were to successfully convert their ideas into

reality, they needed a foundation in materials and processes, with emphasis on their

opportunities and their limitations. He sought to provide a text that could be used in

either a one-or two-semester course designed to meet these objectives. The materials

sections were written with an emphasis on use and application. Processes and machine

tools were described in terms of what they could do, how they do it, and their relative

advantages and limitations, including economic considerations. Recognizing that many

students would be encountering the material for the first time, clear description was

accompanied by numerous visual illustrations.

Paul’s efforts were well received, and the book quickly became the standard text in

many schools and curricula. As materials and processes evolved, advances were incorpo￾rated into subsequent editions. Computer usage, quality control, and automation were

added to the text, along with other topics, so that it continued to provide state-of-the-art

instruction in both materials and processes. As competing books entered the market,

their subject material and organization tended to mimic the DeGarmo text.

Paul DeGarmo retired from active teaching in 1971, but he continued his

research, writing, and consulting for many years. In 1977, after the publication of the

fourth edition of Materials and Processes in Manufacturing, he received a letter from

Ron Kohser, then an assistant professor at the University of Missouri-Rolla who had

many suggestions regarding the materials chapters. DeGarmo asked Ron to rewrite

those chapters for the upcoming fifth edition. After the 5th edition DeGarmo decided

he was really going to retire and after a national search, recruited J T. Black, then a

Professor at Ohio State, to co-author the book with Dr. Kohser.

For the sixth through tenth editions (published in 1984 and 1988 by Macmillan,

1997 by Prentice Hall and 2003 and 2008 by John Wiley & Sons), Ron Kohser and

J T. Black have shared the responsibility for the text. The chapters on engineering

materials, casting, forming, powder metallurgy, additive manufacturing, joining and

non-destructive testing have been written or revised by Ron Kohser. J T. Black has

responsibility for the introduction and chapters on material removal, metrology,

surface finishing, quality control, manufacturing systems design, and lean engineering.

DeGarmo died in 2000, three weeks short of his 93rd birthday. His wife Mary died

in 1995; he is survived by his sons, David and Richard, and many grandchildren. For the

iv Preface

FPREF 02/08/2012 14:29:45 Page 5

10th edition, which coincided with the 50th anniversary of the text, we honored our

mentor with a change in the title to include his name—DeGarmo’s Materials and Pro￾cesses in Manufacturing. We recognize Paul for his insight and leadership and are for￾ever indebted to him for selecting us to carry on the tradition of his book for this, the

11th edition!

& PURPOSE OF THE BOOK

The purpose of this book is to provide basic information on materials, manufacturing

processes and systems to engineers and technicians. The materials section focuses on

properties and behavior. Thus, aspects of smelting and refining (or other material pro￾duction processes) are presented only as they affect manufacturing and manufactured

products. In terms of the processes used to manufacture items (converting materials

into products), this text seeks to provide a descriptive introduction to a wide variety of

options, emphasizing how each process works and its relative advantages and limita￾tions. Our goal is to present this material in a way that can be understood by individuals

seeing it for the very first time. This is not a graduate text where the objective is to thor￾oughly understand and optimize manufacturing processes. Mathematical models and

analytical equations are used only when they enhance the basic understanding of the

material. So, while the text is an introductory text, we do attempt to incorporate new

and emerging technologies like direct-digital-and micro-manufacturing processes as

they are introduced into usage.

& ORGANIZATION OF THE BOOK

E. Paul DeGarmo wanted a book that explained to engineers how the things they

designed are made. DeGarmo’s Materials and Processes in Manufacturing is still

being written to provide a broad, basic introduction to the fundamentals of man￾ufacturing. The book begins with a survey of engineering materials, the ‘‘stuff’’

that manufacturing begins with, and seeks to provide the basic information that

can be used to match the properties of a material to the service requirements of

a component. A variety of engineering materials are presented, along with their

properties and means of modifying them. The materials section can be used in

curricula that lack preparatory courses in metallurgy, materials science, or

strength of materials, or where the student has not yet been exposed to those

topics. In addition, various chapters in this section can be used as supplements to

a basic materials course, providing additional information on topics such as heat

treatment, plastics, composites, and material selection.

Following the materials chapters are sections on casting, forming, powder metal￾lurgy, material removal, and joining. Each section begins with a presentation of the fun￾damentals on which those processes are based. The introductions are followed by a

discussion of the various process alternatives, which can be selected to operate individ￾ually or be combined into an integrated system.

The chapter on rapid prototyping, which had been moved to a web-based supple￾ment in the 10th edition, has been restored to the print text, significantly expanded, and

renamed Additive Processes: Rapid Prototyping and Direct-Digital Manufacturing, to

incorporate the aspects of rapid prototyping, rapid tooling, and direct-digital manufac￾turing, and provide updated information on many recent advances in this area.

Reflecting the growing role of plastics, ceramics and composites, the chapter on

the processes used with these materials has also been expanded.

New to this edition is an Advanced Topic section on lean engineering. The lean

engineer works to transform the mass production system into a lean production system.

To achieve lean production, the final assembly line is converted to a mixed model deliv￾ery system so that the demand for subassemblies and components is made constant. The

conveyor type flow lines are dismantled and converted into U-shaped manufacturing

cells also capable of one-piece flow. The subassembly and manufacturing cells are

linked to the final assembly by a pull system called Kanban (visible record) to form an

integrated production and inventory control system. Hence, economy of scale of the

Preface v

FPREF 02/08/2012 14:29:45 Page 6

mass production system changed to the ‘‘Economy of Scope’’, featuring flexibility,

small lots, superior quality, minimum-inventory and short throughput times.

Later chapters provide an introduction to surface engineering, measurements and

quality control. Engineers need to know how to determine process capability and if they

get involved in six sigma projects, to know what sigma really measures. There is also

introductory material on surface integrity, since so many processes produce the finished

surface and residual stresses in the components.

With each new edition, new and emerging technology is incorporated, and exist￾ing technologies are updated to accurately reflect current capabilities. Through its 50-

plus year history and 10 previous editions, the DeGarmo text was often the first intro￾ductory book to incorporate processes such as friction-stir welding, microwave heating

and sintering, and machining dynamics.

Somewhat open-ended case studies have been incorporated throughout the text.

These have been designed to make students aware of the great importance of properly

coordinating design, material selection, and manufacturing to produce cost competi￾tive, reliable products.

The text is intended for use by engineering (mechanical, lean, manufacturing, and

industrial) and engineering technology students, in both two-and four-year under￾graduate degree programs. In addition, the book is also used by engineers and technolo￾gists in other disciplines concerned with design and manufacturing (such as aerospace

and electronics). Factory personnel will find this book to be a valuable reference that

concisely presents the various production alternatives and the advantages and limita￾tions of each. Additional or more in-depth information on specific materials or pro￾cesses can be found in the expanded list of references that accompanies the text.

& SUPPLEMENTS

For instructors adopting the text for use in their course, an instructor solutions manual is

available through the book website: www.wiley.com/go/global/degarmo. Also available

on the website is a set of PowerPoint lecture slides created by Philip Appel.

Two additional chapters, as well as three Advanced Topic sections, are available

on the book website. These chapters cover: measurement and inspection, non￾destructive inspection and testing, lean engineering, quality engineering, and the enter￾prise (production system). The registration card attached on the inside front cover

provides information on how to access and download this material. If the registration

card is missing, access can be purchased directly on the website www.wiley.com/go/

global/degarmo, by clicking on ‘‘student companion site’’ and then on the links to the

chapter titles.

& ACKNOWLEDGMENTS

The authors wish to acknowledge the multitude of assistance, information, and illustra￾tions that have been provided by a variety of industries, professional organizations, and

trade associations. The text has become known for the large number of clear and helpful

photos and illustrations that have been graciously provided by a variety of sources. In

some cases, equipment is photographed or depicted without safety guards, so as to

show important details, and personnel are not wearing certain items of safety apparel

that would be worn during normal operation.

Over the many editions, there have been hundreds of reviewers, faculty, and stu￾dents who have made suggestions and corrections to the text. We continue to be grate￾ful for the time and interest that they have put into this book. For this edition we

benefited from the comments of the following reviewers:

Jerald Brevick, The Ohio State University; Zezhong Chen, Concordia University;

Emmanuel Enemuoh, University of Minnesota; Ronald Huston, University of

Cincinnati; Thenkurussi Kesavadas, University at Buffalo, The State University of New

York; Shuting Lei, Kansas State University; Lee Gearhart, University at Buffalo,

The State University of New York; ZJ Pei, Kansas State University; Christine Corum,

vi Preface

FPREF 02/08/2012 14:29:45 Page 7

Purdue University; Allen Yi, The Ohio State University; Stephen Oneyear, North

Carolina State; Roger Wright, Rennselaer Polytechnic Institute.

The authors would also like to acknowledge the contributions of Dr. Elliot Stern

for the dynamics of machining section in Chapter 20, Dr. Memberu Lulu for inputs

to the quality chapter, Dr. Lewis Payton for writing the micro manufacturing chapter,

Dr. Subbu Subramanium for inputs to the abrasive chapter, Dr. David Cochran for his

contributions in lean engineering and system design, and Mr. Chris Huskamp of the

Boeing Company for valuable assistance with the chapter on additive manufacturing.

As always, our wives have played a major role in preparing the manuscript. Carol

Black and Barb Kohser have endured being ‘‘textbook widows’’ during the time when

the book was being were written. Not only did they provide loving support, but Carol

also provided hours of expert proofreading, typing, and editing as the manuscript was

prepared.

& ABOUT THE AUTHORS

J T. Black received his Ph.D. from Mechanical and Industrial Engineering, University

of Illinois, Urbana in 1969, an M.S. in Industrial Engineering from West Virginia Uni￾versity in 1963 and his B.S. in Industrial Engineering, Lehigh University in 1960. J T. is

Professor Emeritus from Industrial and Systems Engineering at Auburn University. He

was the Chairman and a Professor of Industrial and Systems Engineering at The Uni￾versity of Alabama-Huntsville. He also taught at The Ohio State University, the Uni￾versity of Rhode Island, the University of Vermont, and the University of Illinois. He

taught his first processes class in 1960 at West Virginia University. J T. is a Fellow in the

American Society of Mechanical Engineers, the Institute of Industrial Engineering and

the Society of Manufacturing Engineers. J loves to write music (mostly down home

country) and poetry, play tennis in the backyard and show his champion pug dog VBo.

Ron Kohser received his Ph.D. from Lehigh University Institute for Metal Form￾ing in 1975. Ron is currently in his 37th year on the faculty of Missouri University of

Science & Technology (formerly the University of Missouri-Rolla), where he is a Pro￾fessor of Metallurgical Engineering and Dean’s Teaching Scholar. While maintaining a

full commitment to classroom instruction, he has served as department chair and Asso￾ciate Dean for Undergraduate Instruction. He currently teaches courses in Metallurgy

for Engineers, Introduction to Manufacturing Processes, and Material Selection, Fabri￾cation and Failure Analysis. In addition to his academic responsibilities, Ron and his

wife Barb operate A Miner Indulgence, a bed-and-breakfast in Rolla, Missouri, and

they enjoy showing their three collector cars.

Preface vii

FPREF 02/08/2012 14:29:45 Page 8

FTOC 02/08/2012 14:32:23 Page 9

CONTENTS

Preface iii

Chapter 1 Introduction to DeGarmo's

Materials and Processes in

Manufacturing 1

1.1 Materials, Manufacturing, and the Standard

of Living 1

1.2 Manufacturing and Production Systems 3

Case Study Famous Manufacturing Engineers 28

Chapter 2 Manufacturing Systems

Design 30

2.1 Introduction 30

2.2 Manufacturing Systems 30

2.3 Control of the Manufacturing System 32

2.4 Classification of Manufacturing Systems 33

2.5 Summary of Factory Designs 49

Case Study Jury Duty for an Engineer 58

Chapter 3 Properties of Materials 59

3.1 Introduction 59

3.2 Static Properties 61

3.3 Dynamic Properties 74

3.4 Temperature Effects (Both High and Low) 79

3.5 Machinability, Formability, and Weldability 83

3.6 Fracture Toughness and the Fracture

Mechanics Approach 83

3.7 Physical Properties 85

3.8 Testing Standards and Testing Concerns 85

Case Study Separation of Mixed Materials 88

Chapter 4 Nature of Metals

and Alloys 89

4.1 Structure–Property–Processing–Performance

Relationships 89

4.2 The Structure of Atoms 90

4.3 Atomic Bonding 90

4.4 Secondary Bonds 92

4.5 Atom Arrangements in Materials 92

4.6 Crystal Structures of Metals 93

4.7 Development of a Grain Structure 94

4.8 Elastic Deformation 95

4.9 Plastic Deformation 96

4.10 Dislocation Theory of Slippage 97

4.11 Strain Hardening or Work Hardening 98

4.12 Plastic Deformation in Polycrystalline Metals 99

4.13 Grain Shape and Anisotropic Properties 100

4.14 Fracture of Metals 101

4.15 Cold Working, Recrystallization, and

Hot Working 101

4.16 Grain Growth 102

4.17 Alloys and Alloy Types 102

4.18 Atomic Structure and Electrical

Properties 103

Chapter 5 Equilibrium Phase

Diagrams and the Iron–Carbon

System 106

5.1 Introduction 106

5.2 Phases 106

5.3 Equilibrium Phase Diagrams 106

5.4 Iron–Carbon Equilibrium Diagram 114

5.5 Steels and the Simplified Iron–Carbon

Diagram 116

5.6 Cast Irons 117

Case Study Fish Hooks 120

Chapter 6 Heat Treatment 121

6.1 Introduction 121

6.2 Processing Heat Treatments 122

6.3 Heat Treatments Used to Increase Strength 125

6.4 Strengthening Heat Treatments for Nonferrous

Metals 125

6.5 Strengthening Heat Treatments for Steel 128

6.6 Surface Hardening of Steel 143

6.7 Furnaces 145

6.8 Heat Treatment and Energy 147

Case Study A Carpenter’s Claw Hammer 150

Chapter 7 Ferrous Metals and

Alloys 152

7.1 Introduction to History-Dependent

Materials 152

7.2 Ferrous Metals 152

7.3 Iron 153

7.4 Steel 154

7.5 Stainless Steels 168

7.6 Tool Steels 171

7.7 Cast Irons 173

7.8 Cast Steels 178

ix

FTOC 02/08/2012 14:32:23 Page 10

7.9 The Role of Processing on Cast Properties 179

Case Study The Paper Clip 181

Chapter 8 Nonferrous Metals and

Alloys 182

8.1 Introduction 182

8.2 Copper and Copper Alloys 183

8.3 Aluminum and Aluminum Alloys 188

8.4 Magnesium and Magnesium Alloys 196

8.5 Zinc and Zinc Alloys 198

8.6 Titanium and Titanium Alloys 199

8.7 Nickel-Based Alloys 201

8.8 Superalloys, Refractory Metals, and

Other Materials Designed for

High-Temperature Service 201

8.9 Lead and Tin, and Their Alloys 203

8.10 Some Lesser-Known Metals and Alloys 204

8.11 Metallic Glasses 204

8.12 Graphite 205

Case Study Hip Replacement Prosthetics 207

Chapter 9 Nonmetallic Materials:

Plastics, Elastomers, Ceramics,

and Composites 208

9.1 Introduction 208

9.2 Plastics 209

9.3 Elastomers 222

9.4 Ceramics 224

9.5 Composite Materials 234

Case Study Lightweight Armor 247

Chapter 10 Material Selection 248

10.1 Introduction 248

10.2 Material Selection and Manufacturing

Processes 252

10.3 The Design Process 252

10.4 Approaches to Material Selection 253

10.5 Additional Factors to Consider 256

10.6 Consideration of the Manufacturing Process 258

10.7 Ultimate Objective 258

10.8 Materials Substitution 260

10.9 Effect of Product Liability on Materials

Selection 261

10.10 Aids to Material Selection 262

Case Study Material Selection 266

Chapter 11 Fundamentals of

Casting 267

11.1 Introduction to Materials Processing 267

11.2 Introduction to Casting 269

11.3 Casting Terminology 270

11.4 The Solidification Process 271

11.5 Patterns 281

11.6 Design Considerations in Castings 284

11.7 The Casting Industry 287

Case Study The Cast Oil-Field Fitting 290

Chapter 12 Expendable-Mold

Casting Processes 291

12.1 Introduction 291

12.2 Sand Casting 292

12.3 Cores and Core Making 307

12.4 Other Expendable-Mold Processes with

Multiple-Use Patterns 311

12.5 Expendable-Mold Processes Using Single-Use

Patterns 313

12.6 Shakeout, Cleaning, and Finishing 320

12.7 Summary 320

Case Study Movable and Fixed Jaw Pieces for a

Heavy-Duty Bench Vise 322

Chapter 13 Multiple-Use-Mold

Casting Processes 323

13.1 Introduction 323

13.2 Permanent-Mold Casting 323

13.3 Die Casting 327

13.4 Squeeze Casting and Semisolid Casting 331

13.5 Centrifugal Casting 333

13.6 Continuous Casting 335

13.7 Melting 336

13.8 Pouring Practice 339

13.9 Cleaning, Finishing, and Heat Treating

of Castings 339

13.10 Automation in Foundry Operations 341

13.11 Process Selection 341

Case Study Baseplate for a Household Steam Iron 344

Chapter 14 Fabrication of Plastics,

Ceramics, and Composites 345

14.1 Introduction 345

14.2 Fabrication of Plastics 345

14.3 Processing of Rubber and Elastomers 359

14.4 Processing of Ceramics 360

14.5 Fabrication of Composite Materials 364

Case Study Automotive and Light Truck Fuel Tanks 378

Chapter 15 Fundamentals of

Metal Forming 379

15.1 Introduction 379

15.2 Forming Processes: Independent Variables 380

15.3 Dependent Variables 382

x Contents

FTOC 02/08/2012 14:32:24 Page 11

15.4 Independent–Dependent Relationships 382

15.5 Process Modeling 383

15.6 General Parameters 384

15.7 Friction and Lubrication Under Metalworking

Conditions 385

15.8 Temperature Concerns 387

15.9 Formability 395

Case Study Interior Tub of a Top-Loading

Washing Machine 397

Chapter 16 Bulk-Forming

Processes 398

16.1 Introduction 398

16.2 Classification of Deformation

Processes 398

16.3 Bulk Deformation Processes 399

16.4 Rolling 399

16.5 Forging 406

16.6 Extrusion 418

16.7 Wire, Rod, and Tube Drawing 424

16.8 Cold Forming, Cold Forging, and Impact

Extrusion 427

16.9 Piercing 431

16.10 Other Squeezing Processes 432

16.11 Surface Improvement by Deformation

Processing 434

Case Study Handle and Body of a Large

Ratchet Wrench 439

Chapter 17 Sheet-Forming

Processes 440

17.1 Introduction 440

17.2 Shearing Operations 440

17.3 Bending 449

17.4 Drawing and Stretching Processes 456

17.5 Alternative Methods of Producing Sheet-Type

Products 471

17.6 Pipe Manufacture 472

17.7 Presses 472

Case Study Automotive Body Panels 480

Chapter 18 Powder Metallurgy 481

18.1 Introduction 481

18.2 The Basic Process 482

18.3 Powder Manufacture 483

18.4 Microcrystalline and Amorphous Material

Produced by Rapid Cooling 484

18.5 Powder Testing and Evaluation 484

18.6 Powder Mixing and Blending 485

18.7 Compacting 485

18.8 Sintering 489

18.9 Recent Advances in Sintering 490

18.10 Hot-Isostatic Pressing 491

18.11 Other Techniques to Produce High-Density

Powder Metallurgy Products 492

18.12 Metal Injection Molding or Powder Injection

Molding 493

18.13 Secondary Operations 495

18.14 Properties of Powder Metallurgy Products 497

18.15 Design of Powder Metallurgy Parts 498

18.16 Powder Metallurgy Products 499

18.17 Advantages and Disadvantages of Powder

Metallurgy 501

18.18 Process Summary 502

Case Study Steering Gear for a Riding Lawn

Mower/Garden Tractor 506

Chapter 19 Additive Processes:

Rapid Prototyping and Direct￾Digital Manufacturing 507

19.1 Introduction 507

19.2 Rapid Prototyping and Direct-Digital

Manufacturing 508

19.3 Layerwise Manufacturing 510

19.4 Liquid-Based Processes 514

19.5 Powder-Based Processes 517

19.6 Deposition-Based Processes 521

19.7 Uses and Applications 524

19.8 Pros, Cons, and Current and Future Trends 528

19.9 Economic Considerations 529

Chapter 20 Fundamentals of

Machining/Orthogonal

Machining 533

20.1 Introduction 533

20.2 Fundamentals 533

20.3 Forces and Power in Machining 541

20.4 Orthogonal Machining (Two Forces) 547

20.5 Chip Thickness Ratio, rc 551

20.6 Mechanics of Machining (Statics) 553

20.7 Shear Strain, g, and Shear Front Angle, w 555

20.8 Mechanics of Machining (Dynamics) 557

20.9 Summary 564

Case Study Orthogonal Plate Machining

Experiment at Auburn University 568

Chapter 21 Cutting Tools for

Machining 569

21.1 Introduction 569

21.2 Cutting Tool Materials 573

Contents xi

FTOC 02/08/2012 14:32:24 Page 12

21.3 Tool Geometry 587

21.4 Tool-Coating Processes 589

21.5 Tool Failure and Tool Life 592

21.6 Flank Wear 593

21.7 Cutting Fluids 599

21.8 Economics of Machining 600

Case Study Comparing Tool Materials Based on

Tool Life 608

Chapter 22 Turning and Boring

Processes 609

22.1 Introduction 609

22.2 Fundamentals of Turning, Boring, and Facing

Turning 611

22.3 Lathe Design and Terminology 617

22.4 Cutting Tools for Lathes 625

22.5 Workholding in Lathes 629

Case Study Estimating the Machining Time

for Turning 636

Chapter 23 Drilling and Related

Hole-Making Processes 637

23.1 Introduction 637

23.2 Fundamentals of the Drilling Process 638

23.3 Types of Drills 640

23.4 Tool Holders for Drills 652

23.5 Workholding for Drilling 654

23.6 Machine Tools for Drilling 654

23.7 Cutting Fluids for Drilling 657

23.8 Counterboring, Countersinking,

and Spot Facing 659

23.9 Reaming 659

Case Study Bolt-down Leg on a Casting 664

Chapter 24 Milling 665

24.1 Introduction 665

24.2 Fundamentals of Milling Processes 665

24.3 Milling Tools and Cutters 672

24.4 Machines for Milling 678

Case Study HSS versus Tungsten

Carbide Milling 685

Chapter 25 NC/CNC Processes and

Adaptive Control: A(4) and A(5)

Levels of Automation 686

25.1 Introduction 686

25.2 Basic Principles of Numerical Control 686

25.3 Machining Center Features and Trends 702

25.4 Ultra-High-Speed Machining Centers 705

25.5 Summary 706

Chapter 26 Abrasive Machining

Processes 710

26.1 Introduction 710

26.2 Abrasives 711

26.3 Grinding Wheel Structure and Grade 717

26.4 Grinding Wheel Identification 722

26.5 Grinding Machines 726

26.6 Honing 734

26.7 Superfinishing 736

26.8 Free Abrasives 738

26.9 Design Considerations in Grinding 742

Case Study Process Planning for the MfE 744

Chapter 27 Workholding Devices

for Machine Tools 745

27.1 Introduction 745

27.2 Conventional Fixture Design 745

27.3 Tool Design Steps 748

27.4 Clamping Considerations 749

27.5 Chip Disposal 751

27.6 Unloading and Loading Time 752

27.7 Example of Jig Design 752

27.8 Types of Jigs 754

27.9 Conventional Fixtures 755

27.10 Modular Fixturing 757

27.11 Setup and Changeover 759

27.12 Clamps 761

27.13 Other Workholding Devices 762

27.14 Economic Justification of Jigs and Fixtures 765

Case Study Fixture versus No Fixture

in Milling 770

Chapter 28 Nontraditional

Manufacturing Processes 771

28.1 Introduction 771

28.2 Chemical Machining Processes 773

28.3 Electrochemical Machining Processes 779

28.4 Electrical Discharge Machining 786

Case Study Vented Cap Screws 798

Chapter 29 Fundamentals

of Joining 799

29.1 Introduction to Consolidation Processes 799

29.2 Classification of Welding and Thermal

Cutting Processes 800

29.3 Some Common Concerns 801

29.4 Types of Fusion Welds and Types of Joints 801

29.5 Design Considerations 804

29.6 Heat Effects 804

xii Contents

FTOC 02/08/2012 14:32:24 Page 13

29.7 Weldability or Joinability 811

29.8 Summary 812

Chapter 30 Gas Flame and

Arc Processes 814

30.1 Oxyfuel-Gas Welding 814

30.2 Oxygen Torch Cutting 818

30.3 Flame Straightening 820

30.4 Arc Welding 821

30.5 Consumable-Electrode Arc Welding 823

30.6 Nonconsumable-Electrode Arc Welding 831

30.7 Welding Equipment 836

30.8 Arc Cutting 838

30.9 Metallurgical and Heat Effects in

Thermal Cutting 840

Case Study Bicycle Frame Construction and Repair 842

Chapter 31 Resistance- and

Solid-State Welding

Processes 844

31.1 Introduction 844

31.2 Theory of Resistance Welding 844

31.3 Resistance-Welding Processes 847

31.4 Advantages and Limitations of Resistance

Welding 852

31.5 Solid-State Welding Processes 853

Case Study Manufacture of an Automobile

Muffler 863

Chapter 32 Other Welding

Processes, Brazing,

and Soldering 864

32.1 Introduction 864

32.2 Other Welding and Cutting Processes 864

32.3 Surface Modification by Welding-Related

Processes 873

32.4 Brazing 876

32.5 Soldering 885

Case Study Impeller of a Pharmaceutical Company

Industrial Shredder/Disposal 891

Chapter 33 Adhesive Bonding,

Mechanical Fastening,

and Joining of Nonmetals 892

33.1 Adhesive Bonding 892

33.2 Mechanical Fastening 901

33.3 Joining of Plastics 905

33.4 Joining of Ceramics and Glass 907

33.5 Joining of Composites 908

Case Study Golf Club Heads with Insert 910

Chapter 34 Surface Engineering 912

34.1 Introduction 912

34.2 Abrasive Cleaning and Finishing 922

34.3 Chemical Cleaning 927

34.4 Coatings 930

34.5 Vaporized Metal Coatings 940

34.6 Clad Materials 940

34.7 Textured Surfaces 940

34.8 Coil-Coated Sheets 941

34.9 Edge Finishing and Burrs 941

Case Study Dana Lynn’s Fatigue Lesson 946

Chapter 35 Microelectronic

Manufacturing and Electronic

Assembly 949

35.1 Introduction 949

35.2 How Electronic Products Are Made 949

35.3 Semiconductors 950

35.4 How Integrated Circuits Are Made 951

35.5 How the Silicon Wafer Is Made 954

35.6 Fabricating Integrated Circuits on Silicon

Wafers 955

35.7 Thin-Film Deposition 962

35.8 Integrated Circuit Packaging 968

35.9 Printed Circuit Boards 975

35.10 Electronic Assembly 980

Chapter 36 Micro/Meso/Nano

Fabrication Processes 986

36.1 Introduction 986

36.2 Additive Processes 987

36.3 Metrology at the Micro/Meso/

Nano Level 1002

Chapter 37 Measurement and

Inspection 1005

(Web Based Chapter)

(www.wiley.com/go/global/DeGarmo)

37.1 Introduction 1005

37.2 Standards of Measurement 1006

37.3 Allowance and Tolerance 1011

37.4 Inspection Methods for

Measurement 1018

37.5 Measuring Instruments 1020

37.6 Vision Systems for Measurement 1029

37.7 Coordinate Measuring Machines 1030

37.8 Angle-Measuring Instruments 1031

37.9 Gages for Attributes Measuring 1033

Case Study Measuring an Angle 1040

Contents xiii