Principles. Manufacturing

Transcription

1 Principles of Modem Manufacturing SI Version Fifth Edition Mikell R 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. Wiley

2 CONTENTS 1 INTRODUCTION AND OVERVIEW OF MANUFACTURING Polymers Composites What Is Manufacturing? Materials in Manufacturing Manufacturing Processes Production Systems Manufacturing Economics Recent Developments in Manufacturing 27 6 DIMENSIONS, SURFACES, AND THEIR MEASUREMENT Dimensions, Tolerances, and Related Attributes Measuring Instruments and Gages Surfaces 142 Part I Material Properties and Product Attributes Measurement of Surfaces Effect of Manufacturing Processes THE NATURE OF MATERIALS Atomic Structure and the Elements 37 Part II Solidification Processes 2.2 Bonding between Atoms and Molecules Crystalline Structures Noncrystalline (Amorphous) Structures Engineering Materials 49 7 FUNDAMENTALS OF METAL CASTING Overview of Casting Technology Heating and Pouring Solidification and Cooling MECHANICAL PROPERTIES OF MATERIALS Stress-Strain Relationships Hardness Effect oftemperature on Properties Fluid Properties Viscoelastic Behavior of Polymers 76 8 METAL CASTING PROCESSES Sand Casting Other Expendable-Mold Casting Processes Permanent-Mold Casting Processes Foundry Practice PHYSICAL PROPERTIES OF MATERIALS Volumetric and Melting Properties Thermal Properties Casting Quality Metals for Casting Product Design Considerations Mass Diffusion Electrical Properties Electrochemical Processes 91 5 ENGINEERING MATERIALS Metals and Their Alloys Ceramics GLASSWORKING Raw Materials Preparation and Melting Shaping Processes in Glassworking Heat Treatment and Finishing Product Design Considerations 217

3 ImQjQP Contents 10 SHAPING PROCESSES FOR PLASTICS Properties of Polymer Melts Processing of Cermets Product Design Considerations Extrusion Production of Sheet and Film Fiber and Filament Production (Spinning) 236 Part IV Metal Forming Metalworking 335 and Sheet 10.5 Coating Processes Injection Molding Compression and Transfer Molding Blow Molding and Rotational Molding Thermoforming Casting Polymer Foam Processing and Forming Product Design Considerations PROCESSING OF POLYMER MATRIX COMPOSITES AND RUBBER Overview of PMC Processing Open Mold Processes Closed Mold Processes Other PMC Shaping Processes Rubber Processing and Shaping Manufacture of Tires and Other Rubber Products 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 386?art III Particulate Processing of Metals and Ceramics SHEET METALWORKING Cutting Operations POWDER METALLURGY Characterization of Engineering Powders Production of Metallic Powders Conventional Pressing and Sintering Alternative Pressing and Sintering Techniques Materials and Products for Powder Metallurgy Design Considerations in Powder Metallurgy PROCESSING OF CERAMICS AND CERMETS Processing of Traditional Ceramics Processing of New Ceramics 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 433 Part V Material Removal Processes THEORY OF METAL MACHINING Overview of Machining Technology Theory of Chip Machining 444 Formation in Metal

4 Contents ^HBBSSS^SiSS fflsffll 17.3 Force Relationships and the Merchant Equation Power and Energy Relationships in Machining Cutting Temperature MACHINING OPERATIONS AND MACHINE TOOLS Machining and Part Geometry Turning and Related Operations Drilling and Related Operations Milling Machining Centers and Turning Centers Other Machining Operations Machining Operations for Special Geometries 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 610 Part VI Property Enhancing and Surface Processing Operations HEAT TREATMENT OF METALS Annealing Martensite Formation in Steel Precipitation Hardening Surface Hardening Heat Treatment Methods and Facilities SURFACE PROCESSING OPERATIONS Industrial Cleaning Processes Diffusion and Ion Implantation Plating and Related Processes Conversion Coating Vapor Deposition Processes Organic Coatings Porcelain Enameling and Other Ceramic Coatings Thermal and Mechanical Coating Processes 651 Part VII Joining and Assembly Processes 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 693

5 Contents 26.5 Solid-State Welding Weld Quality Wettability Design Considerations in Welding BRAZING, SOLDERING, AND ADHESIVE BONDING Brazing Soldering Adhesive Bonding ELECTRONICS ASSEMBLY AND PACKAGING Electronics Packaging Printed Circuit Boards Printed Circuit Board Assembly Electrical Connector Technology MICROFABRICATION TECHNOLOGIES Microsystem Products Microfabrication Processes 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 746 Part VIII Special Processing and Assembly Technologies RAPID PROTOTYPING AND ADDITIVE MANUFACTURING Fundamentals of Rapid Prototyping and Additive Manufacturing Additive Manufacturing Processes Cycle Time and Cost Analysis Additive Manufacturing Applications PROCESSING OF INTEGRATED CIRCUITS Overview of IC Processing Silicon Processing Lithography Layer Processes Used in IC Fabrication Integrating the Fabrication Steps IC Packaging Yields in IC Processing NANOFABRICATION TECHNOLOGIES Nanotechnology Products and Applications Introduction to Nanoscience Nanofabrication Processes 858 Part IX Manufacturing Systems AUTOMATION TECHNOLOGIES FOR MANUFACTURING SYSTEMS Automation Fundamentals Hardware for Automation Computer Numerical Control Industrial Robotics INTEGRATED MANUFACTURING SYSTEMS Material Handling Fundamentals of Production Lines Manual Assembly Lines Automated Production Lines Cellular Manufacturing Flexible Manufacturing Systems and Cells Computer Integrated Manufacturing 924 Part X Manufacturing Support Systems PROCESS PLANNING AND PRODUCTION CONTROL Process Planning Other Manufacturing Engineering Functions 940

6 Contents CSSI 36.3 Production Planning and Control Just-In-Time Delivery Systems Lean Production QUALITY CONTROL AND INSPECTION 37.1 Product Quality Process Capability and Tolerances Statistical Process Control Quality Programs in Manufacturing Inspection Principles Modern Inspection Technologies 977 APPENDIX 987 INDEX 991