MANUFACTURING ENGINEERING

AND TECHNOLOGYSIXTH EDITION IN SI UNITS

Serope KalpakjianIllinois Institute of Technology

Steven R. SchmidThe University

of Notre DameSI Conversion by

Hamldon MusaUniversiti Teknologi Malaysia

Prentice HallSingapore London New York Toronto Sydney Tokyo Madrid Mexico City Munich Paris Capetown Hong Kong Montreal

xiv

lt gives us great pleasure to acknowledge the assistance of the following colleagues in the preparation and publication of this edition of the book: Komel F. Ehmann, Northwestern University; Klaus J .Weinmann, University of California at Berkeley; Timotius Pasang, AUT University; Miguel Sells Canto, Escola Politecnica Superior dAlcoi, Universitat Politcnica de Valencia, Spain; and Kevin Wilson, Michael Giordano and Megan McGann, University of Notre Dame.We also acknowledge Kent M. Kalpakjian as the original author ofthe chapter on Fabrication of Microelectronic Devices.We would like to thank our editor, Holly Stark, at Prentice Hall for her enthusiastic support and guidance; and Clare Romeo, Production Editor, for her meticulous editorial and production supervision. We would also like to acknowledge the help of the following in the production of this edition of the book: Greg Dulles, A/V Project Manager; Daniel Sandin, Media Editor; William Opaluch, Editorial Assistant; and Kenny Beck, Cover Design. We are happy to present below a cumulative list of all those individuals who generously have made numerous contributions to various editions of our two

books.B.J. AaronsonS. S.

Abella D. Adams K. Anderson S. Arellano D.D. Arola R.A. Arlt V. Aronov A. Bagchi E.D. Baker J. Barak J. Ben-Ari G.F. Benedict S. Bhattacharyya JT. Black W. Blanchard C. Blathras G. Boothroyd D. Bourell B. Bozak N.N. Breyer C.A. Brown R.G. Bruce J Cesarone T.-C. Chang R.L. Cheaney A. ChedaR.

Chelikani Chen

D. FurrerR.

Giese

S.-W. Choi A. Cinar

E. Goode

R.O. Colantonio P. Cotnoir P.J. Courtney P. Demers D. Descoteaux M.F. DeVries R.C. Dix M. Dollar D.A. Domfeld H.I. Douglas M. Dugger D.R. Durham D. Duvall S.A. Dynan J. El Gomayel M.G. Elliott N.X. Fang E.C. Feldy J. Field G.W. Fischer D.A. Fowley R.L. French B.R. Fruchter

K.L. Graham P. Grigg M. GrujicicP.J. GuichelaarB.

Harriger

D. Harry

M. Hawkins R.J. Hocken E.M. Honig, Jr. Y. Huang S. ImamR.

Jaeger

C. Johnson

K. Jones D. Kalisz

K.M. Kalpakjian J. Kamman S.G. Kapoor R. Kassing R.L. Kegg W.J. Kennedy R. Kerr T. Kesavadas B.D. King

J.E. Kopf R.J. Koronkowski

C. Nair

L. Soisson

P.G. Nash

Kotowski S. Krishnamachari K.M. Kulkami T. Lach L. Langseth M. Laurent M. LevineJ

Nazemetz E.M. OdomJ

N. Pacelli U. PalS.

Paolucci

S.J. ParelukarT. Pasang Z.J. PeiJ

B.S. LevyJ. Lewandowski

Penaluna

X.Z. Li Z. Liang B.W. LillyA. Lozier

C. Petronis

M. Philpott M. Pradheeradhi

D.A. Lucca M. Madou S. MantellL. Mapa A. Marsan R.J. MatticeC. Maziar

T. McClelland W. McClurg L. McGuire

K.E. McKee K.P. Meade M.H. MillerR.

Miller

T.S. Milo D.J. MorrisonS.

Mostovoy

J.M. Prince D.W. Radford W.J. Riffe R.J. Rogalla Y. Rong A.A. Runyan P. Saha G.S. Saletta M. Salimian M. Savic W.J. Schoech S.A. Schwartz M. Selles S. Shepel R. Shivpuri M.T. Siniawski J.E. Smallwood J .P. Sobczak

Stewart Stocker L. Strom A.B. Strong K. Subramanian T. Sweeney W.G. Switalski T. Taglialavore M. Tarabishy K.S. Taraman R. Taylor B.S. Thakkar A. Trager A. Tseng C. Tszang M. Tuttle S. Vaze J. Vigneau G.A. Volk G. Wallace J.F. Wang K.J. Weinmann R. Wertheim K. West J. Widmoyer K.R. Williams G. Williamson B. Wiltjer J. Wingfield P.K. Wright N. ZabarasP.J

We are also grateful to numerous organizations. companies, and individuals who supplied us with many ofthe illustrations and case studies. These contributions have been specifically acknowledged throughout the text.It is with joy that we gratefully dedicate this book to Professor John A. Schey, our esteemed colleague and distinguished researcher and author, who has been a wise and great teacher, not only to generations of students but to his many colleagues as well. He and his wife, Gitta, have been treasured friends for

many years.

SEROPE KALPAKJIAN STEVEN R. SC HMID JANUARY 2009

xvi

About the AuthorSerope Kalpakjian is a professor emeritus of mechanical and materials engineering at the Illinois Institute of Technology, Chicago. He is the author of Mechanical Processing of Materials (Van Nostrand, 1967) and co-author of Lubricants and Lubrication in Metalworking Operations (with E.S. Nachtman, Dekker, 1985). Both of the first editions of his books Manufacturing Processes for Engineering Materials (Addison-Wesley, 1984) and Manufacturing Engineering and Technology (Addison Wesley, 1989) have received the M. Eugene Merchant Manufacturing Textbook Award of SME. He has conducted research in several areas in manufacturing processes, is the author of numerous technical papers and articles in professional journals, handbooks, and encyclopedias, and has edited several conference proceedings. He also has been editor and co-editor of various technical journals and has served on the editorial board of Encyclopedia Americana.Professor Kalpakjian has received the Forging Industry Educational and Research Foundation Best Paper Award (1966); the Excellence in Teaching Award from the Illinois Institute of Technology (1970); the ASME Centennial Medallion (1980); the SME International Education Award (1989); a Person of the Millennium Award from IIT (1999); the Albert Easton White Outstanding Teacher Award from ASM International (2000); and the SME Outstanding Young Manufacturing Engineer Award for 2002 was named after him. Professor Kalpakjian is a Life Fellow of ASME; Fellow of SME; Fellow and Life Member of ASM International; Fellow Emeritus of The International Academy for Production Engineering (CIRP); and is a past president and founding member of the North American Manufacturing Research Institution/ SME. He is a high-honors graduate of Robert College (Istanbul), Harvard University, and the Massachusetts Institute of Technology.

XVII

About the AuthorSteven R. Schmid is an Associate Professor in the Department of Aerospace and Mechanical Engineering at the University of Notre Dame, where he teaches and conducts research in the general areas of manufacturing, machine design, and tribology. He received his Bachelors degree in Mechanical Engineering from the Illinois Institute of Technology (with Honors) and Masters and Ph.D. degrees, both in Mechanical Engineering, from Northwestern University. He has received numerous awards, including the John T. Parsons Award from SME (2000); the Newkirk Award from ASME (2000); the Kaneb Center TeachingAward (2000 and 2003); and the Ruth and Joel Spira Award for Excellence in Teaching (2005). He is also the recipient of a National Science Foundation CAREERS Award (1996) and an ALCOA Foundation Award (1994).

Professor Schmid is the author of almost l00 technical papers, has coauthored the texts Fundamentals of Machine Elements (McGraw-Hill), Fundamentals of Fluid Film Lubrication (Dekker), Manufacturing Processes for Engineering Materials (Prentice Hall), and has contributed two chapters to the CRC Handbook of Modern Tribology. He is an Associate Editor of the ASME Journal of Manufacturing Science and Engineering, and is a registered Professional Engineer and a Certified Manufacturing Engineer of SME.

About the AdaptorHamidon Musa is Associate Professor with the Manufacturing Division in the Faculty of Mechanical Engineering at Universiti Teknologi Malaysia. He graduated from the University of Birmingham in 1980 and did his postgraduate studies at Cranfield Institute of Technology, UK. His main area ofinterest is non-traditional machining.

ContentsGeneral Introduction1.1 1.2 1.3

1

1.41.5

1.6 1.71.8

1.9

1.10 1.11

What 1s Manufacturing? 1 Product Design and Concurrent Engineering 8 Design for Manufacture, Assembly, Disassembly, and Service Green Design and Manufacturing 13 Selection of Materials 15 Selection of Manufacturing Processes 18 Computer-integrated Manufacturing 26 Quality Assurance and Total Quality Management 29 Lean Production and Agile Manufacturing 32 Manufacturing Costs and Global Competition 32 General Trends in Manufacturing 34

11

Part1

l:

Fundamentals of Materials: Their Behavior and Manufacturing Properties 3740

The Structure of Metals1.1

Introduction 40 1.2 Types of Atomic Bonds 41 1.3 The Crystal Structure of Metals 42 1.4 Deformation and Strength of Single Crystals 44 1.5 Grains and Grain Boundaries 47 1.6 Plastic Deformation of Polycrystalline Metals 50 1.7 Recovery, Recrystallization, and Grain Growth 51 1.8 Cold, Warm, and Hot Working 52 Summary 53 Key Terms 53 Bibliography 54 Review Questions 54 Qualitative Problems 54 Quantitative Problems 55 Synthesis, Design, and Projects

55

2

Mechanical Behavior, Testing, ancl Manufacturing Properties of Materials2.1

56

2.22.3

Introduction 56 Tension 57 Compression 66XIX

2.4 2.5 2.6 2.7

Torsion 67 Bending (Flexure) 68 Hardness 68 Fatigue 74 2.8 Creep 75 2.9 Impact 75 2.10 Failure and Fracture of Materials in Manufacturing and in Service 76 Residual Stresses 81 2.11 Work, Heat, and Temperature 82 2.12 Bibliography 84 Summary 83 Key Terms 84 Qualitative Problems 85 Review Questions 84 Quantitative Problems 85 Synthesis, Design, and Projects

86

Physical Properties of Materials3.1 3.2 3.3

88

Introduction

88

Density 89 Melting Point 92 3.4 Specific Heat 92 3.5 Thermal Conductivity 93 3.6 Thermal Expansion 93 Electrical, Magnetic, and Optical Properties 94 3.7 3.8 Corrosion Resistance 95 Bibliography 98 Summary 97 Key Terms 97 Qualitative Problems 98 Review Questions 98 Quantitative Problems 98 Synthesis, Design, and Projects

99

Metal Alloys: Their Structure and Strengthening 100 by Heat Treatment4.1

4.24.3

4.4 4.5 4.6 4.74.8

4.94.10 4.11 4.12 4.13

100 Structure of Alloys 101 Phase Diagrams 103 The Iron-Carbon System 107 The Iron-Iron-carbide Phase Diagram and the Development of Microstructures in Steels 108 Cast Irons 110 Heat Treatment of Ferrous Alloys 111 Hardenability of Ferrous Alloys 1 15 Heat Treatment of Nonferrous Alloys and Stainless Steels 117 Case Hardening 119 Annealing 121 Heat-treating Furnaces and Equipment 123 Design Considerations for Heat Treating 125

Introduction

XX

Key Terms 127 Bibliography 127 Summary 126 Review Questions 127 Qualitative Problems 127 Quantitative Problems 128 Synthesis, Design, and Projects

128

Ferrous Metals and Alloys; Production, General Properties, and Applications 1295.1 5.2 5.3

5.45.5

Introduction 129 Production of Iron and Steel 130 Casting of Ingots 133 Continuous Casting 134 Carbon and Alloy Steels 136

5.6 Stainless Steels 143 5.7 Tool and Die Steels 145 Summary 147 Key Terms 148 Bibliography 148 Review Questions 148 Qualitative Problems 149 Quantitative Problems 149 Synthesis, Design, and Projects

150

Nonferrous Metals and Alloys: Production, General Properties, and Applications 1516.1 6.2 6.3 6.4 6.5 6.6

6.76.8 6.9

Introduction 151 Aluminum and Aluminum Alloys 152 Magnesium and Magnesium Alloys 157 Copper and Copper Alloys 158 Nickel and Nickel Alloys 160 Superalloys 161 Titanium and Titanium Alloys 162 Refractory Metals and Alloys 163Beryllium164

Zirconium 164 6.11 Low-melting Alloys 164 Precious Metals 166 6.12 6.13 Shape-memory Alloys (Smart Materials) 166 6.14 Amorphous Alloys (Metallic Glasses) 167 6.15 Metal Foams 167 Summary 168 Key Terms 168 Bibliography 169 Review Questions 169 Qualitative Problems 169 Quantitative Problems 170 Synthesis, Design, and Projects6.10

170

Polymers: Structure, General Properties, and Applications 1717.1 7.2 7.3 7.4

Introduction 171 The Structure of Polymers 173 Thermoplastics 180 Thermosetting Plastics 184

XXI

Additives in Plastics 184 General Properties and Applications of Thermoplastics General Properties and Applications of Thermosetting 7.7 Plastics 188 Biodegradable Plastics 190 7.8 Elastomers (Rubbers) 191 7.9 Key Terms 193 Bibliography 193 Summary 192 Qualitative Problems 194 Review Questions 194 Synthesis, Design, and Projects Quantitative Problems 1957.5 7.6

185

195

8

Ceramics, Graphite, Diamond, and Nanomaterials: Structure, General Properties, and Applications 1968.1 8.2 8.3 8.4 8.5 8.6 8.7 8.8

Introduction 196 The Structure of Ceramics 197 General Properties and Applications of CeramicsGlasses 205 Glass Ceramics Graphite 208

201

207

Diamond 210 Nanomaterials 210 Bibliography 213 Summary 212 Key Terms 212 Qualitative Problems 214 Review Questions 213 Quantitative Problems 214 Synthesis, Design, and Projects

214

9

Composite Materials: Structure, General Properties, and Applications 216Introduction 216 The Structure of Reinforced Plastics 217 Properties of Reinforced Plastics 222 Applications of Reinforced Plastics 225 Metal-matrix Composites 227 Ceramic-matrix Composites 229 9.7 Other Composites 230 Key Terms 231 Bibliography 231 Summary 231 Qualitative Problems 232 Review Questions 232 Synthesis, Design, and Projects Quantitative Problems 2339.1 9.2 9.3 9.4 9.5 9.6

233

Part II: Metal-Casting Processes ancl Equipment 235

l0

Fundamentals of Metal Casting10.1 10.2

237

Introduction

237 Solidification of Metalsxxii

238

ll

Fluid Flow 243 Fluidity of Molten Metal 245 Heat Transfer 247 10.6 Defects 249 Summary 253 Key Terms 254 Bibliography 254 Review Questions 254 Qualitative Problems 255 Quantitative Problems 25 5 Synthesis, Design, and Projects10.3 10.4 10.5

256

Metal-Casting Processes and Equipment11.1 11.2 11.3 11.4 11.5

258

Introduction 258 Expendable-mold, Permanent-pattern Casting Processes 262 Expendable-mold, Expendable-pattern Casting Processes 270 Permanent-mold Casting Processes 277 Casting Techniques for Single-crystal Components 285 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 291 Qualitative Problems 291 Quantitative Problems 292 Synthesis, Design, and Projects 292

I2

Metal Casting: Design, Materials, and Economics 294Introduction 294 Design Considerations in Casting 294 Casting Alloys 302 Economics of Casting 307 Summary 308 Key Terms 309 Bibliography 309 Review Questions 309 Qualitative Problems 309 Quantitative Problems 310 Synthesis, Design, and Projects12.1 12.2 12.3 12.4

310

Part Ill: Forming and Shaping Processes and Equipment 3131

3

Metal-Rolling Processes and EquipmentThe Flat-rolling Process 318 Flat-rolling Practice 322 13.4 Rolling Mills 325 13.5 Various Rolling Processes and Mills 327 Summary 332 Key Terms 333 Bibliography 333 Review Questions 333 Qualitative Problems 333 Quantitative Problems 334 Synthesis, Design, and Projectsxxiii

316

13.1 13.2 13.3

Introduction

316

334

Metal-Forging Processes and EquipmentIntroduction 335 Open-die Forging 337 14.3 Impression-die and Closed-die Forging 339 14.4 Various Forging Operations 343 14.5 Forgeability of Metals; Forging Defects 348 14.6 Die Design, Die Materials, and Lubrication 349 14.7 Die-manufacturing Methods and Die Failures 351 14.8 Forging Machines 353 14.9 Economics of Forging 355 358 Bibliography 358 Summary 357 Key Terms Qualitative Problems 358 Review Questions 358 Quantitative Problems 359 Syntbesis, Design, and Projects14.1 14.2

335

359

Metal Extrusion and Drawing Processes and Equipment 360Introduction 360 The Extrusion Process 362 15.3 Hot Extrusion 364 15.4 Cold Extrusion 368 15.5 Extrusion Defects 371 15.6 Extrusion Equipment 373 15.7 The Drawing Process 373 15.8 Drawing Practice 375 15.9 Drawing Defects and Residual Stresses 377 15.10 Drawing Equipment 377 Bibliography 379 Summary 378 Key Terms 378 Review Questions 379 Qualitative Problems 379 Quantitative Problems 380 Syntbesis, Design, and Projects15.1

15.2

380

Sheet-Metal Forming Processes and Equipment 38116.1 16.2 16.3 16.4 16.5 16.6

Introduction

16.716.8 16.9 16.10 16.11

381 Shearing 382 Sheet-metal Characteristics and Formability 392 Forrnability Tests for Sheet Metals 394 Bending Sheets, Plates, and Tubes 397 Miscellaneous Bending and Related Operations 401 Deep Drawing 407 Rubber Forming and Hydroforming 413 Spinning 417 Superplastic Forming 420 Specialized Forming Processes 421XXIV

16.12 Manufacturing of Metal Honeycomb Structures 426 16.13 Design Considerations in Sheet-metal Forming 428 16.14 Equipment for Sheet-metal Forming 430 16.15 Economics of Sheet-forming Operations 431 Summary 432 Key Terms 433 Bibliography 433 Review Questions 434 Qualitative Problems 434 Quantitative Problems 435 Synthesis, Design, and Projects 435

Powder-Metal Processing and EquipmentIntroduction 437 Production of Metal Powders 438 Compaction of Metal Powders 444 Sintering 452 Secondary and Finishing Operations 456 Design Considerations 457 17.7 Process Capabilities 459 17.8 Economics of Powder Metallurgy 460 Summary 462 Key Terms 462 Bibliography 463 Review Questions 463 Qualitative Problems 463 Quantitative Problems 464 Synthesis, Design, ana' Projects17.1 17.2 17.3 17.4 17.5 17.6

437

464

Ceramics, Glasses, and Superconductors: Processing and Equipment 465465 Shaping Ceramics 466 Forming and Shaping of Glass 472 Techniques for Strengthening and Annealing Glass 476 Design Considerations for Ceramics and Glasses 478 Processing of Superconductors 479 Summary 480 Key Terms 481 Bibliography 481 Revieu/ Questions 482 Qualitative Problems 482 Quantitative Problems 482 Synthesis, Design, and Projects 48318.1 18.2 18.3 18.4 18.5 18.6

Introduction

Plastics and Composite Materials: Forming

and Shaping19.1 19.2 19.3 19.4 19.5 19.6

484

19.719.8 19.9

Introduction 484 Extrusion 486 Injection Molding 493 Blow Molding 499 Rotational Molding 501 Thermoforming 502 Compression Molding 503 Transfer Molding 504 Casting 505XXV

19.10 Foam Molding 506 19.11 Cold Forming and Solid-phase Forming 507 19.12 Processing Elastomers 507 19.13 Processing Polymer-matrix Composites 508 19.14 Processing Metal-matrix and Ceramic-matrix Composites 517 19.15 Design Considerations 518 19.16 Economics of Processing Plastics and Composite Materials 520 Key Terms 522 Bibliography 522 Summary 521 Qualitative Problems 523 Review Questions 523 Synthesis, Design, and Projects 524 Quantitative Problems 524

Z0

Rapid-Prototyping Processes and Operations 52520.1

Introduction 525

20.2 Subtractive Processes 528 20.3 Additive Processes 530 20.4 Virtual Prototyping 541 Direct Manufacturing and Rapid Tooling 542 20.5 Key Terms 549 Bibliography 549 Summary 549 Qualitative Problems 550 Review Questions 550 Quantitative Problems 55 0 Synthesis, Design, and Projects

551

Part

IV:

Machining Processes and Machine Tools 553556

21

Fundamentals of Machining

21.1 Introduction 5 5 6 21.2 Mechanics of Cutting 558 21.3 Cutting Forces and Power 568 21.4 Temperatures in Cutting 571 21.5 Tool Life: Wear and Failure 574 21.6 Surface Finish and Integrity 581 21.7 Machinability 583 Key Terms 588 Bibliography 588 Summary 587 Qualitative Problems 589 Review Questions 588 Quantitative Problems 5 89 Synthesis, Design, and Projects

590

22

Cutting-Tool Materials and Cutting Fluids22.1 22.2 22.3 22.4 22.5

591

Introduction 591 High-speed Steels 595 Cast-cobalt Alloys 596 Carbides 5 96 Coated Tools 600XXVI

22.6 Alumina-based Ceramics 604 22.7 Cubic Boron Nitride 605 22.8 Silicon-nitride-based Ceramics 605 22.9 Diamond 605 22.10 Whisker-reinforced Materials and Nanomaterials 606 22.11 Tool Costs and Reconditioning of Tools 607 22.12 Cutting Fluids 607 Summary 612 Key Terms 612 Bibliography 613 Review Questions 613 Qualitative Problems 613 Quantitative Problems 614 Synthesis, Design, and Projects

614

Machining Processes: Turning and Hole Making 615Introduction 615 23.2 The Turning Process 618 23.3 Lathes and Lathe Operations 626 23.4 Boring and Boring Machines 641 23.5 Drilling, Drills, and Drilling Machines 643 23.6 Reaming and Reamers 652 23.7 Tapping and Taps 653 Summary 655 Key Terms 656 Bibliography 656 Review Questions 656 Qualitative Problems 657 Quantitative Problems 657 Synthesis, Design, ana' Projects23.1

658

Machining Processes: Milling, Broaching, Sawing Filing, and Gear Manufacturing 65924.1 Introduction 659 24.2 Milling and Milling Machines 660 24.3 Planing and Shaping 674 24.4 Broaching and Broaching Machines 675 24.5 Sawing 678 24.6 Filing 681 24.7 Gear Manufacturing by Machining 681 Summary 689 Key Terms 690 Bibliography 690 Review Questions 690 Qualitative Problems 691 Quantitative Problems 691 Synthesis, Design, ana' Projects

692

Machining Centers, Machine-Tool Structures, and Machining Economics 69325.1

25.2 25.3 25.4 25.5

Introduction 693 Machining Centers 694 Machine-tool Structures 702 Vibration and Chatter in Machining Operations High-speed Machining 709XXVII

706

25.6 Hard Machining 711 25.7 Ultraprecision Machining 711 25.8 Machining Economics 713 Key Terms 717 Bibliography 717 Summary 717 Qualitative Problems 718 Review Questions 717 Quantitative Problems 718 Synthesis, Design, and Projects

718

26

Abrasive Machining and Finishing Operations 71926.1 Introduction 719 26.2 Abrasives and Bonded Abrasives 721 26.3 The Grinding Process 727 26.4 Grinding Operations and Machines 736 26.5 Design Considerations for Grinding 744 26.6 Ultrasonic Machining 744 26.7 Finishing Operations 746 26.8 Deburring Operations 750 26.9 Economics of Abrasive Machining and Finishing Operations 753 Key Terms 755 Bibliography 755 Summary 754 Qualitative Problems 75 6 Review Questions 756 Quantitative Problems 757 Synthesis, Design, and Projects 757

27

Advanced Machining Processes 759Introduction 759 27.1 27.2 Chemical Machining 761 27.3 Electrochemical Machining 765 27.4 Electrochemical Grinding 768 27.5 Electrical-discharge Machining 769 27.6 Laser-beam Machining 774 27.7 Electron-beam Machining 777 27.8 Water-jet Machining 778 27.9 Abrasive-jet Machining 779 27.10 Hybrid Machining Systems 780 27.11 Economics of Advanced Machining Processes 781 Key Terms 784 Bibliography 784 Summary 784 Qualitative Problems 785 Review Questions 785 Quantitative Problems 785 Synthesis, Design, and Projects

786

Part V: Niicromanufacturing and Fabrication of Microelectronic Devices 787

28

Fabrication of Microelectronic Devices28.1 28.2

790

Introduction

790 Clean Rooms 793XXV111

28.3 Semiconductors and Silicon 794 28.4 Crystal Growing and Wafer Preparation 795 28.5 Film Deposition 798 28.6 Oxidation 799 28.7 Lithography 800 28.8 Etching 808 28.9 Diffusion and Ion Implantation 816 28.10 Metallization and Testing 818 28.11 Wire Bonding and Packaging 820 28.12 Yield and Reliability 825 28.13 Printed Circuit Boards 826 Summary 827 Key Terms 828 Bibliography 828 Review Questions 829 Qualitative Problems 829 Quantitative Problems 830 Synthesis, Design, and Projects

830

29

Fabrication of Microelectromechanical Devices and Systems and Nanoscale Manufacturing 83129.1 Introduction 831 29.2 Micromachining of MEMS Devices 833 29.3 The LIGA Microfabrication Process 844 29.4 Solid Free-form Fabrication of Devices 850 Nanoscale Manufacturing 855 29.5 Summary 858 Key Terms 858 Bibliography 858 Review Questions 859 Qualitative Problems 859 Quantitative Problems 860 Synthesis, Design, and Projects

860

Part

VI:

joining Processes and Equipment 861865

30

Fusion-Welding Processes30.1

Introduction 865 30.2 Oxyfuel-gas Welding 866 30.3 Arc-Welding Processes: Nonconsumable Electrode 869 30.4 Arc-welding Processes: Consumable Electrode 873 30.5 Electrodes for Arc Welding 879 30.6 Electron-beam Welding 880 30.7 Laser-beam Welding 880 30.8 Cutting 882 30.9 The Weld joint, Quality, and Testing 884 30.10 Joint Design and Process Selection 893 Summary 897 Key Terms 897 Bibliography 898 Review Questions 898 Qualitative Problems 898 Quantitative Problems 899 Synthesis, Design, and Projects 899XXIX

31

Solid-State Welding Processes31.1

900

Introduction

31.2 31.3 31.4 31.5

900 Cold Welding and Roll Bonding Ultrasonic Welding 902

901

Friction Welding 903 Resistance Welding 905 3 1.6 Explosion Welding 913 Diffusion Bonding 914 31.7 31.8 Economics of Welding Operations 916 Bibliography 919 Summary 918 Key Terms 919 Review Questions 919 Qualitative Problems 919 Quantitative Problems 920 Synthesis, Design, and Projects

920

32

Brazing, Soldering, Adhesive-Bonding,

and Mechanical-Fastening Processes 92132.1

Introduction

921

32.2 Brazing 922 32.3 Soldering 926 32.4 Adhesive Bonding 931 32.5 Mechanical Fastening 939 joining Plastics, Ceramics, and Glasses 942 32.6 32.7 Economics of ]oining Operations 945 Key Terms 947 Bibliography 947 Summary 946 Review Questions 947 Qualitative Problems 948 Quantitative Problems 948 Synthesis, Design, and Projects

948

Part Vll: Surface Technology

949

33

Surface Roughness and Measurement; Friction, Wear, and Lubrication 95133.1

Introduction

951

33.2 Surface Structure and Integrity 952 33.3 Surface Texture and Roughness 953 33.4 Friction 957 33.5 Wear 961 33.6 Lubrication 964 Metalworking Fluids and Their Selection 966 33.7 Summary 970 Key Terms 970 Bibliography 971 Review Questions 971 Qualitative Problems 971 Quantitative Problems 972 Synthesis, Design, and Projects

972

XXX

34

Surface Treatments, Coatings, and Cleaning34.1

973

Introduction 973 34.2 Mechanical Surface Treatments 974 34.3 Mechanical Plating and Cladding 976 34.4 Case Hardening and Hard Facing 976 34.5 Thermal Spraying 977 34.6 Vapor Deposition 979 34.7 Ion Implantation and Diffusion Coating 982 34.8 Laser Treatments 982 34.9 Electroplating, Electroless Plating, and Electroforming 983 34.10 Conversion Coatings 986 34.11 Hot Dipping 987 34.12 Porcelain Enameling; Ceramic and Organic Coatings 988 34.13 Diamond Coating and Diamondlike Carbon 989 34.14 Surface Texturing 990 34.15 Painting 990 34.16 Cleaning of Surfaces 991 Summary 993 Key Terms 993 Bibliography 993 Review Questions 994 Qualitative Problems 994 Quantitative Problems 994 Synthesis, Design, ana' Projects 995

Part VIII: Engineering Metrology, Instrumentation, and Quality Assurance 997

35

Engineering Metrology and Instrumentation 998Introduction 998 Measurement Standards 999 Geometric Features of Parts; Analog and Digital Measurements 1000 35.4 Traditional Measuring Methods and Instruments 1001 35.5 Modern Measuring Instruments and Machines 1008 35.6 Automated Measurement and Inspection 1011 35.7 General Characteristics and Selection of Measuring Instruments 1012 35.8 Geometric Dimensioning and Tolerancing 1012 Summary 1017 Key Terms 1017 Bibliography 1017 Review Questions 1018 Qualitative Problems 1 018 Quantitative Problems 1018 Synthesis, Design, and Projects35.1

35.2 35.3

1019

XXXI

36

Quality Assurance, Testing, and InspectionIntroduction 1020 36.2 Product Quality 1021 36.3 Quality Assurance 1022 36.4 Total Quality Management 1023 36.5 Taguchi Methods 1025 The ISO and QS Standards 1029 36.6 36.7 Statistical Methods of Quality Control 1030 36.8 Statistical Process Control 1033 36.9 Reliability of Products and Processes 1039 36.10 Nondestructive Testing 1040 36.11 Destructive Testing 1044 36.12 Automated Inspection 1044 Bibliography 1046 Summary 1045 Key Terms 1045 Qualitative Problems 1047 Review Questions 1046 Quantitative Problems 1047 Synthesis, Design, and Projects36.1

1020

1047

Part IX: Manufacturing in a Competitive Environment 1049

37

Automation of Manufacturing Processes37.1

1051

37.2 37.3 37.4 37.5 37.6 37.7 37.8 37.9 37.10

Introduction 1051 Automation 1053 Numerical Control 1060 Adaptive Control 1066 Material Handling and Movement Industrial Robots 1071 Sensor Technology 1077 Flexible Fixturing 1081Assembly Systems

1068

1083 Design Considerations for Fixturing, Assembly, Disassembly, and Servicing 1086 37.11 Economic Considerations 1089 Bibliography 1090 Summary 1089 Key Terms 1090 Review Questions 1091 Qualitative Problems 1091 Synthesis, Design, and Projects 1092 Quantitative Problems 1 092

38

Computer-Aided Manufacturing 109338.1

38.2 38.3

Introduction 1093 Manufacturing Systems 1094 Computer-integrated Manufacturing

1094

Xxxii

Computer-aided Design and Engineering 1097 Computer-aided Manufacturing 1104 Computer-aided Process Planning 1104 Computer Simulation of Manufacturing Processes and Systems 1107 38.8 Group Technology 1108 Summary 1115 Key Terms 1 1 15 Bibliography 1115 Review Questions 1 1 1 6 Qualitative Problems 1 1 1 6 Synthesis, Design, and Projects 1 1 1 638.4 38.5 38.6 38.7

39

Computer-Integrated Manufacturing Systems 71 1 1

Introduction 1 1 17 39.2 Cellular Manufacturing 1 1 1 8 39.3 Flexible Manufacturing Systems 1120 39.4 Holonic Manufacturing 1122 39.5 just-in-time Production 1 124 39.6 Lean Manufacturing 1125 39.7 Communications Networks in Manufacturing 1 127 39.8 Artificial Intelligence 1 129 39.9 Economic Considerations 1132 Summary 1132 Key Terms 1133 Bibliography 1133 Review Questions 1134 Qualitative Problems 1134 Synthesis, Design, and Projects 113439.1

40

Product Design and Process Selection in a Competitive Environment 1351

40.1 Introduction 1135 40.2 Product Design 1 136 40.3 Product Quality and Life Expectancy 1139 40.4 Life-cycle Assessment and Sustainable Manufacturing 1140 40.5 Material Selection for Products 1142 40.6 Material Substitution 1146 40.7 Manufacturing Process Capabilities 1 148 40.8 Process Selection 1152 40.9 Manufacturing Costs and Cost Reduction 1 156 Summary 11 61 Key Terms 11 61 Bibliography 1 1 62 Review Questions 1 1 62 Qualitative Problems 1 1 62 Synthesis, Design, and Projects 1163

Index 165 List of Tables 177 References to Various Topics List of Examples 1801 1 1XXX11l

1

179

Case Studies11.1: Lost-foam Casting of Engine Blocks 272 11.2: Investment Casting of Total Knee Replacements 275 14.1: Manufacture of a Stepped Pin by Heading and Piercing Operations 345 14.2: Suspension Components for the Lotus Elise Automobile 356 16.1: Manufacturing of Food and Beverage Cans 412 16.2: Tube Hydroforming of an Automotive Radiator Closure 415

Cymbal Manufacture 424 Powder Metallurgy Parts in a Snowblower 461 Production of High-temperature Superconducting Tapes 480 Manufacture of Head ProtectorTM Tennis Racquets 515 Invisalign Orthodontic Aligners 543 23.1: Bone Screw Retainer 654 24.1: Ping Golf Putter 688 27.1: Electrochemical Machining of a Biomedical Implant 767 27.2: Manufacture of Small Satellites 781 29.1: Digital Micromirror Device 837 29.2: Accelerometer for Automotive Air Bags 851 31.1: Friction Welding of Pistons 917 32.1: Light Curing Acrylic Adhesives for Medical Products 937 36.1: Manufacture of Television Sets by Sony Corporation 1028 36.2: Dimensional Control of Plastic Parts in Saturn Automobiles 1038 37.1: Robotic Deburring of a Blow-molded Toboggan 1076 38.1: CAD Model Development for Automotive Components 1101 40.1: Automobile Tires: From Cradle-to-grave to Cradle-to-cradle 114116.3: 17.1: 18.1: 19.1: 20.1:

XXXIV

General Introductionl.l

What ls Manufacturing?

I.I

What lsManufacturing? Product Design and Concurrent Engineering 8 Design for Manufacture, Assembly, Disassembly, and Service Green Design and Manufacturing I3 Selection of Materials I5 Selection of Manufacturing Processes I8 Computer-integrated Manufacturing 26 Quality Assurance and Total Quality Management 29 Lean Production and Agile Manufacturing 32 Manufacturing Costs and Global Competition 32 General Trends in Manufacturing 34I I I

manufacturing. The word manufacture first appeared in English in 1567 and is derived from the Latin manu factus, meaning made by hand. The word manufacturing first appeared in 1683, and the word production, which is often used interchangeably with the word manufacturing, first appeared sometime during the 15th century. Manufacturing is concerned with making products. A manufactured product may itself be used to make other products, such as (a) a large press, to shape flat sheet metal into automobile bodies, (b) a drill, for producing holes, (c) industrial sawing machines, for making clothing at high rates, and (d) numerous pieces of machinery, to produce an endless variety of individual items, ranging from thin wire for guitars and electric motors to crankshafts and connecting rods for automotive engines (Fig. I.1). Note that items such as bolts, nuts, and paper clips are discrete products, meaning individual items. By contrast, a roll of aluminum foil, a spool of wire, and metal or plastic tubing are continuous products, which are then cut into individual pieces of various lengths for specific purposes. Because a manufactured item typically starts with raw materials, which are then subjected to a sequence of processes to make individual products, it has a certain value. For example, clay has some value as mined, but when it is made into a product such as cookware, pottery, an electrical insulator, or a cutting tool, value is added to the clay. Similarly, a nail has a value over and above the cost of the short piece of wire or rod from which it is made. Products such as computer chips, electric motors, and professional athletic shoes are known as high-value-added products.Brief History of Manufacturing. Manufacturing dates back to the period 5000-4000 B.C. (Table LZ), and thus, it is older than recorded history, the earliest forms of which were invented by the Sumerians around 3500 B.C. Primitive caveA

As you begin to read this chapter, take a few moments to inspect various objects around you: mechanical pencil, light fixture, chair, cell phone, and computer. You soon will note that all these objects, and their numerous individual components, are made from a variety of materials and have been produced and assembled into the items that you now see. You also will note that sofne objects, such as a paper clip, nail, spoon, and door key, are made of a single component. However, as shown in Table 1.1, the vast majority of objects around us consist of numerous individual pieces that are built and assembled by a combination of processes called

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28

General Introduction

TABLE

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Approximate Number of Parts in ProductsCommon pencil Rotary lawn mower Grand piano AutomobileBoeing 747-4004

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-1Polymer manifolds removed for clarity

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Graphite-coated castaluminium pistons

l.l Illustration of an automotive engine (the Duratec V-6), showing various components and the materials used in making them. Source: Courtesy of Ford Motor Company. Illustration by D. Kimball.FIGURE

drawings, as well as markings on clay tablets and stone, needed (1) some form of a brush and some sort of paint, as in the prehistoric cave paintings in Lascaux, France, estimated to be 16,000 years old; (2) some means of scratching the clay tablets and baking them, as in cuneiforrn scripts and pictograrns of 3000 B.C.; and (3) simple tools for making incisions and carvings on the surfaces of stone, as in the hieroglyp/vs in ancient Egypt. The manufacture of items for specific uses began with the production of various household artifacts, which were typically made of either wood, stone, or metal. The materials first used in making utensils and ornamental objects included gold, copper, and iron, followed by silver, lead, tin, bronze (an alloy of copper and tin), and brass (an alloy of copper and zinc). The processing methods first employed involved mostly casting and /vanirnering, because they were relatively easy to perform. Over the centuries, these simple processes gradually began to be developed into more and more complex operations, at increasing rates of production and higher levels of product quality. Note, for example, from Table I.2 that lathes for cutting screw threads already were available during the period from 1600 to 1700, but it was not until some three centuries later that automatic screw machines were developed.

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