FUNDAMENTALS OF MODERN MANUFACTURING

Transcription

1 FUNDAMENTALS OF MODERN MANUFACTURING Materials, Processes, and Systems Third Edition 2008 AGI-Information Management Consultants May be used for personal purporses only or by libraries associated to dandelon.com network. Mikell P. Groover Professor of Industrial and Systems Engineering Lehigh University The author gratefully acknowledges the valuable contributions of Professor Gregory L. Tonkay, Associate Professor of Industrial and Systems Engineering Lehigh University. JOHN WILEY & SONS, INC.

2 CONTENTS 1 INTRODUCTION AND OVERVIEW OF MANUFACTURING What Is Manufacturing? Materials in Manufacturing Manufacturing Processes Production Systems Organization of the Book 20 Part I Material Properties and Product Attributes 2 THE NATURE OF MATERIALS Atomic Structure and the Elements Bonding between Atoms and Molecules Crystalline Structures Noncrystalline (Amorphous) Structures Engineering Materials 35 3 MECHANICAL PROPERTIES OF MATERIALS Stress-Strain Relationships Hardness Effect of Temperature on Properties Fluid Properties Viscoelastic Behavior of Polymers 60 4 PHYSICAL PROPERTIES OF MATERIALS Volumetric and Melting Properties Thermal Properties Mass Diffusion Electrical Properties Electrochemical Processes 75 5 DIMENSIONS, TOLERANCES, AND SURFACES Dimensions, Tolerances, and Related Attributes Surfaces Effect of Manufacturing Processes 87 Part II Engineering Materials 6 METALS Alloys and Phase Diagrams Ferrous Metals Nonferrous Metals Superalloys Guide to the Processing of Metals CERAMICS Structure and Properties of Ceramics Traditional Ceramics New Ceramics Glass Some Important Elements Related to Ceramics Guide to Processing Ceramics POLYMERS Fundamentals of Polymer Science and Technology Thermoplastic Polymers Thermosetting Polymers Elastomers Guide to the Processing of Polymers COMPOSITE MATERIALS Technology and Classification of Composite Materials Metal Matrix Composites Ceramic Matrix Composites Polymer Matrix Composites Guide to Processing Composite Materials 191 Part III Solidification Processes 10 FUNDAMENTALS OF METAL CASTING Overview of Casting Technology Heating and Pouring Solidification and Cooling METAL CASTING PROCESSES Sand Casting Other Expendable-Mold Casting Processes Permanent-Mold Casting Processes Foundry Practice Casting Quality Metals for Casting Product Design Considerations 242 IX

3 Contents 12 GLASSWORKING Raw Materials Preparation and Melting Shaping Processes in Glassworking Heat Treatment and Finishing Product Design Considerations SHAPING PROCESSES FOR PLASTICS Properties of Polymer Melts Extrusion Production of Sheet and Film Fiber and Filament Production (Spinning) Coating Processes Injection Molding Compression and Transfer Molding Blow Molding and Rotational Molding Thermoforming Casting Polymer Foam Processing and Forming Product Design Considerations RUBBER-PROCESSING TECHNOLOGY Rubber Processing and Shaping Manufacture of Tires and Other Rubber Products Product Design Considerations SHAPING PROCESSES FOR POLYMER MATRIX COMPOSITES Starting Materials for PMCs Open Mold Processes Closed Mold Processes Filament Winding Pultrusion Processes Other PMC Shaping Processes 333 Part IV Particulate Processing of Metals and Ceramics 16 POWDER METALLURGY Characterization of Engineering Powders Production of Metallic Powders Conventional Pressing and Sintering Alternative Pressing and Sintering Techniques Materials and Products for PM Design Considerations in Powder Metallurgy PROCESSING OF CERAMICS AND CERMETS Processing of Traditional Ceramics Processing of New Ceramics Processing of Cermets Product Design Considerations 375 Part V Metal Forming and Sheet Metalworking 18 FUNDAMENTALS OF METAL FORMING Overview of Metal Forming Material Behavior in Metal Forming Temperature in Metal Forming Strain Rate Sensitivity Friction and Lubrication in Metal Forming BULK DEFORMATION PROCESSES IN METALWORKING Rolling Other Deformation Processes Related to Rolling Forging Other Deformation Processes Related to Forging Extrusion Wire and Bar Drawing SHEET METALWORKING Cutting Operations Bending Operations Drawing Other Sheet-Metal-Forming Operations Dies and Presses for Sheet-Metal Processes Sheet-Metal Operations Not Performed on Presses Bending of Tube Stock 474 Part VI Material Removal Processes 21 THEORY OF METAL MACHINING Overview of Machining Technology Theory of Chip Formation in Metal Machining Force Relationships and the Merchant Equation Power and Energy Relationships in Machining Cutting Temperature MACHINING OPERATIONS AND MACHINE TOOLS Turning and Related Operations Drilling and Related Operations Milling 522

4 Contents XI 22.4 Machining Centers and Turning Centers Other Machining Operations High-Speed Machining CUTTING-TOOL TECHNOLOGY Tool Life Tool Materials Tool Geometry Cutting Fluids ECONOMIC AND PRODUCT DESIGN CONSIDERATIONS IN MACHINING Machinability Tolerances and Surface Finish Selection of Cutting Conditions Product Design Considerations in Machining GRINDING AND OTHER ABRASIVE PROCESSES Grinding Related Abrasive Processes NONTRADITIONAL MACHINING AND THERMAL CUTTING PROCESSES Mechanical Energy Processes Electrochemical Machining Processes Thermal Energy Processes Chemical Machining Application Considerations 641 Part VII Property Enhancing and Surface Processing Operations 27 HEAT TREATMENT OF METALS Annealing Martensite Formation in Steel Precipitation Hardening Surface Hardening Heat Treatment Methods and Facilities CLEANING AND SURFACE TREATMENTS Chemical Cleaning Mechanical Cleaning and Surface Preparation Diffusion and Ion Implantation COATING AND DEPOSITION PROCESSES Plating and Related Processes Conversion Coatings Physical Vapor Deposition Chemical Vapor Deposition Organic Coatings Porcelain Enameling and Other Ceramic Coatings Thermal and Mechanical Coating Processes 684 Part VIM Joining and Assembly Processes 30 FUNDAMENTALS OF WELDING Overview of Welding Technology The Weld Joint Physics of Welding Features of a Fusion-Welded Joint WELDING PROCESSES Arc Welding Resistance Welding Oxyfuel Gas Welding Other Fusion-Welding Processes Solid-State Welding Weld Quality Weldability Design Considerations in Welding BRAZING, SOLDERING, AND ADHESIVE BONDING Brazing Soldering Adhesive Bonding MECHANICAL ASSEMBLY Threaded Fasteners Rivets and Eyelets Assembly Methods Based on Interference Fits Other Mechanical Fastening Methods Molding Inserts and Integral Fasteners Design for Assembly 778 Part IX Special Processing and Assembly Technologies 34 RAPID PROTOTYPING Fundamentals of Rapid Prototyping Rapid Prototyping Technologies Application Issues in Rapid Prototyping PROCESSING OF INTEGRATED CIRCUITS Overview of IC Processing 799

5 XII Contents 35.2 Silicon Processing Lithography Layer Processes Used in IC Fabrication Integrating the Fabrication Steps IC Packaging Yields in IC Processing ELECTRONICS ASSEMBLY AND PACKAGING Electronics Packaging Printed Circuit Boards Printed Circuit Board Assembly Surface-Mount Technology Electrical Connector Technology MICROFABRICATION TECHNOLOGIES Microsystem Products Microfabrication Processes NANOFABRICATION TECHNOLOGIES Introduction to Nanotechnology Nanofabrication Processes The National Nanotechnology Initiative 884 Part X Manufacturing Systems 39 NUMERICAL CONTROL AND INDUSTRIAL ROBOTICS Numerical Control Industrial Robotics GROUP TECHNOLOGY AND FLEXIBLE MANUFACTURING SYSTEMS Group Technology Flexible Manufacturing Systems PRODUCTION LINES Fundamentals of Production Lines Manual Assembly Lines Automated Production Lines 930 Part XI Manufacturing Support Systems 42 MANUFACTURING ENGINEERING Process Planning Problem Solving and Continuous Improvement Concurrent Engineering and Design for Manufacturability PRODUCTION PLANNING AND CONTROL Aggregate Planning and the Master Production Schedule Inventory Control Material and Capacity Requirements Planning Just-In-Time and Lean Production Shop Floor Control QUALITY CONTROL What Is Quality? Process Capability Statistical Tolerancing Taguchi Methods Statistical Process Control MEASUREMENT AND INSPECTION Metrology Inspection Principles Conventional Measuring Instruments and Gages Measurement of Surfaces Advanced Measurement and Inspection Technologies 1004 INDEX 1015