Principles of modern manufacturing

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FEATURES OF THIS BOOK AND ITS WEBSITE

FOR STUDENTS:

Principles of Modern Manufacturing contains 37 chapters. Chapter 1 provides an

introduction and overview of manufacturing. Chapters 2 through 6 are concerned

with engineering materials and their properties, as well as product attributes;

Chapters 7 through 33 cover manufacturing processes and related technologies;

and Chapters 34 through 37 describe the systems of manufacturing.

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

in the book:

➢ More than 360 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 700 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 dis￾cussed in the book.

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.

➢ 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.

3GFCOVER.indd 1 30/11/12 3:11 PM

➢ 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 fold￾er 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.

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.

3GFCOVER.indd 2 30/11/12 3:11 PM

Principles

of Modern

Manufacturing

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.

SI Version

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Copyright © 2013, 2011 John Wiley & Sons Singapore Pte. Ltd.

Cover image from © hywit dimyadi/iStockphoto

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ISBN: 978-1-118-47420-4

Printed in Asia

10 9 8 7 6 5 4 3 2 1

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iii

PREFACE

Principles of Modern Manufacturing is designed for a fi rst course or two-course

sequence in manufacturing at the junior level in mechanical, industrial, and man￾ufacturing engineering curricula. It may be appropriate for technology programs

related to the preceding engineering disciplines. Most of the book’s content is

concerned with manufacturing processes, but it also provides coverage of engi￾neering materials and production systems. Materials, processes, and systems are

the basic building blocks of modern manufacturing and the three broad subject

areas covered 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 36 chapters are organized into 10 parts. Part I, titled Engi￾neering Materials and Product Attributes, consists of fi ve chapters that describe

the important characteristics of engineering materials and the products made

from them.

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iv Preface

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

four categories: (1) solidifi cation processes, (2) particulate processes, (3) deformation

processes, and (4) material removal processes. Part II consists of fi ve chapters on the

solidifi cation processes that include casting of metals, glassworking, and polymer

shaping. In Part III, the processing of powders of metals and ceramics is covered in

two chapters. Part IV deals with metal deformation processes such as rolling, forg￾ing, extrusion, and sheet metalworking. Finally, Part V discusses the material re￾moval processes. Four chapters are devoted to machining, and two chapters cover

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

technologies.

Part VI 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 VII, 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 VIII, titled Special Processing and Assembly Tech￾nologies. Its fi ve chapters cover rapid prototyping and additive manufacturing,

processing of integrated circuits, electronics assembly, microfabrication, and nano￾fabrication.

Part IX 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 manufacturing

systems. Finally, Part X deals with manufacturing support systems: process plan￾ning, production planning and control, lean production, and quality control and

inspection.

NEW TO THIS EDITION

This fi fth edition builds on the fourth edition. Additions and changes in the fi fth edi￾tion include the following:

➢ The chapter count has been reduced from 39 to 37 through consolidation of

several chapters. The three chapters in the fourth edition on engineering mate￾rials (Chapters 6, 7, and 8) have been combined into a single chapter, and the

two chapters in the fourth edition on manufacturing engineering (Chapter 37)

and production planning and control (Chapter 38) have been combined into

one chapter. Chapter 34 on microfabrication and nanofabrication in the fourth

edition has been expanded to two chapters, owing to the growing importance

of these topics in manufacturing.

➢ 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.

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Preface v

➢ 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

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 coverage of 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

45 in the fourth edition to 63 in the fi fth. Included are new example problems

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

costs, and integrated circuit processing.

➢ Many of the end-of-chapter problems are new or revised. 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 in 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.

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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.

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

ACKNOWLEDGEMENTS

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 30.15 (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

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viii Acknowledgements

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

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

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

Linda Ratts, Project Editor Gladys Soto, and Senior Production Editor Sinchee

Tham for their advice and efforts on behalf of the book. And fi nally, I want to ac￾knowledge 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 Manufac￾turing Technology Laboratory; and Marcia Groover, my wife and colleague at the

University. I sometimes write textbooks about how computers are used in manufac￾turing, but when my computer needs fi xing, she is the one I call on.

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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 thirteen 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.

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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. An International, modifi ed edition of this

book was published in 2011 with the title “Principles of Modern Manufacturing.”

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

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

Edition, John Wiley & Sons, Inc., 2013.

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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 82

4.1 Volumetric and Melting Properties 82

4.2 Thermal Properties 85

4.3 Mass Diffusion 87

4.4 Electrical Properties 89

4.5 Electrochemical Processes 91

5 ENGINEERING MATERIALS 94

5.1 Metals and Their Alloys 94

5.2 Ceramics 108

5.3 Polymers 115

5.4 Composites 123

6 DIMENSIONS, SURFACES, AND

THEIR MEASUREMENT 131

6.1 Dimensions, Tolerances, and

Related Attributes 132

6.2 Measuring Instruments and Gages 133

6.3 Surfaces 142

6.4 Measurement of Surfaces 148

6.5 Effect of Manufacturing Processes 150

Part II Solidifi cation Processes

7 FUNDAMENTALS OF METAL

CASTING 154

7.1 Overview of Casting Technology 157

7.2 Heating and Pouring 159

7.3 Solidifi cation and Cooling 163

8 METAL CASTING PROCESSES 174

8.1 Sand Casting 174

8.2 Other Expendable-Mold

Casting Processes 180

8.3 Permanent-Mold Casting

Processes 186

8.4 Foundry Practice 196

8.5 Casting Quality 200

8.6 Metals for Casting 202

8.7 Product Design Considerations 204

9 GLASSWORKING 209

9.1 Raw Materials Preparation and

Melting 209

9.2 Shaping Processes in Glassworking 210

9.3 Heat Treatment and Finishing 216

9.4 Product Design Considerations 217

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