FTOC indd xviFTOC indd xvi 71812 1 46 PM71812 1 46 PM FEATURES OF THIS BOOK AND ITS WEBSITE FOR STUDENTS Fundamentals of Modern Manufacturing Materials, Processes, and Systems con tains 40 chapters Chapter 1 provides an introduction and overview of manufactur ing Chapters 2 through 9 are concerned with engineering materials and product attributes; Chapters 10 through 36 cover manufacturing processes and related tech nologies; and Chapters 37 through 40 describe the systems of manufacturing T.
FTOC.indd xvi 7/18/12 1:46 PM FEATURES OF THIS BOOK AND ITS WEBSITE FOR STUDENTS: Fundamentals of Modern Manufacturing: Materials, Processes, and Systems contains 40 chapters Chapter provides an introduction and overview of manufacturing Chapters through are concerned with engineering materials and product attributes; Chapters 10 through 36 cover manufacturing processes and related technologies; and Chapters 37 through 40 describe the systems of manufacturing To assist in the learning process for students, the following materials are provided in the book: ➢ More than 550 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 750 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 discussed in the book ➢ Units used in the book (International System and U.S Customary System) are provided in the inside back cover, which also includes procedures for converting between SI and USCS units 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 Students 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 website, 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 FCOVER.indd 7/18/12 2:05 PM ➢ 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 ➢ 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 folder 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 ➢ A set of case studies developed by Prof Dan Waldorf of California Polytechnic University at San Luis Obispo These case studies are designed to be used in conjunction with the video clips located on the website as well as the book Instructors can use these materials as homework or laboratory exercises 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 FCOVER.indd 7/18/12 2:05 PM Fundamentals of Modern Manufacturing Materials, Processes, and Systems 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 FFIRS.indd i 8/9/12 12:03 AM VICE PRESIDENT AND EXECUTIVE PUBLISHER Don Fowley ACQUISITION EDITOR Linda Ratts SENIOR CONTENT MANAGER Lucille Buonocore SENIOR PRODUCTION EDITOR Anna Melhorn SENIOR DESIGNER Jim O’Shea EDITORIAL ASSISTANT Christopher Teja MARKETING MANAGER Christopher Ruel CREATIVE DIRECTOR Harry Nolan PRODUCTION SERVICES Suzanne Ingrao/Ingrao Associates FRONT COVER PHOTO Courtesy of Kennametal, Inc This book was set in Times Roman by Thomson Digital, and printed and bound by Quad Graphics/Versailles This book is printed on acid-free paper ∞ 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 Copyright © 2013, 2010, 2008, 2004 John Wiley & Sons, Inc All rights reserved 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 Sections 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 07030-5774, (201) 748-6011, fax (201) 748-6008, website www.wiley.com/go/permissions Evaluation copies are provided to qualified academics and professionals for review purposes only, for use in their courses during the next academic year These copies are licensed and may not be sold or transferred to a third party Upon completion of the review period, please return the evaluation copy to Wiley Return instructions and a free-of-charge return shipping label are available at www.wiley.com/go/returnlabel If you have chosen to adopt this textbook for use in your course, please accept this book as your complimentary desk copy Outside of the United States, please contact your local representative 978-1-118-231463 Printed in the United States of America 10 FFIRS.indd ii 8/9/12 12:03 AM PREFACE Fundamentals of Modern Manufacturing: Materials, Processes, and Systems is designed for a first course or two-course sequence in manufacturing at the junior level in mechanical, industrial, and manufacturing engineering curricula Given its coverage of engineering materials, it may also be suitable for materials science and engineering courses that emphasize materials processing Finally, it may be appropriate for technology programs related to the preceding engineering disciplines Most of the book’s content is concerned with manufacturing processes (about 65% of the text), but it also provides significant coverage of engineering 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, polymers, and composite materials), (2) its inclusion of recently developed manufacturing processes in addition to the traditional processes that have been used and refined 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 significantly 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 manufacturing 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 first book on manufacturing processes to provide a quantitative engineering coverage of the topic ORGANIZATION OF THE BOOK The first chapter provides an introduction and overview of manufacturing Manufacturing is defined, and the materials, processes, and systems of manufacturing are briefly 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 39 chapters are organized into 11 parts Part I, titled Material Properties and Product Attributes, consists of four chapters that describe the important characteristics of materials and the products made from them Part II discusses the four basic engineering materials: metals, ceramics, polymers, and composites iii FPREF.indd iii 7/18/12 12:18 PM iv Preface Part III begins the coverage of the part-shaping processes, which are organized into four categories: (1) solidification processes, (2) particulate processes, (3) deformation processes, and (4) material removal processes Part III consists of six chapters on the solidification processes that include casting of metals, glassworking, and polymer shaping In Part IV, the processing of powders of metals and ceramics is covered in two chapters Part V deals with metal deformation processes such as rolling, forging, extrusion, and sheet metalworking Finally, Part VI discusses the material removal processes Four chapters are devoted to machining, and two chapters cover grinding (and related abrasive processes) and the nontraditional material removal technologies Part VII 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, electroplating, vapor deposition processes, and coating (painting) Joining and assembly processes are considered in Part VIII, which is organized into four chapters on welding, brazing, soldering, adhesive bonding, and mechanical assembly Several unique processes that not neatly fit into the preceding classification scheme are covered in Part IX, titled Special Processing and Assembly Technologies Its five chapters cover rapid prototyping and additive manufacturing, processing of integrated circuits, electronics assembly, microfabrication, and nanofabrication Part X 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 flexible manufacturing systems Finally, Part XI deals with manufacturing support systems: process planning, production planning and control, lean production, and quality control and inspection NEW TO THIS EDITION This fifth edition builds on the fourth edition The content has been increased and this is reflected in the page count In previous editions, the author has attempted to keep the page count at around 1000 The fifth edition contains about 1100 pages Additions and changes in the fifth edition include the following: ➢ The chapter count has been reduced from 42 to 40 through consolidation of several chapters The two chapters in the fourth edition on rubber processing (Chapter 14) and polymer matrix composites processing (Chapter 15) have been combined into a single chapter, and the two chapters in the fourth edition on process planning (Chapter 40) and production planning and control (Chapter 41) have been combined into one chapter ➢ In Chapter 1, two new sections have been added on manufacturing economics (cycle time and cost analysis) and recent developments that have affected manufacturing ➢ Troubleshooting guides have been added to several of the machining chapters ➢ The chapter on rapid prototyping has been extensively revised, and a new section on cycle time and cost analysis has been added The chapter title has been FPREF.indd iv 7/18/12 12:18 PM Preface ➢ ➢ ➢ ➢ ➢ ➢ ➢ ➢ ➢ ➢ v changed to Rapid Prototyping and Additive Manufacturing to reflect the evolution 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 emphasis on surface mount technology A new section on the classification of nanotechnology products has been added to the chapter on 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 47 in the fourth edition to 65 in the fifth Included are new example problems on manufacturing economics, tensile testing, machining time, rapid prototyping costs, and integrated circuit processing More than 60% of the end-of-chapter problems are new or revised, and the total number of end-of-chapter problems has been increased End-of-chapter problems have been labeled as using either SI or USCS units, so if instructors want to assign problems with only one type of units, this will help them identify the problems that are of the desired type 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 from 495 in the fourth edition to 745 for the fifth edition The DVD that was included with the fourth edition has now been made available 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 available 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 endof-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 FPREF.indd v 7/18/12 12:18 PM 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 ➢ A set of case studies developed by Prof Dan Waldorf of California Polytechnic University is available on the website for the book These case studies are designed to be used in conjunction with the video clips located on the website Instructors can use these materials as homework or laboratory exercises 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 verified Individual questions or comments may be directed to the author personally at Mikell.Groover@Lehigh.edu FPREF.indd vi 7/18/12 12:18 PM 1090 Index Bloom, 430 Blow forming, 335 Blow molding, 328–333 Blowing, glass, 289–291 Blown-film extrusion, 312–313, 340 Body-centered cubic (BCC), 42–43 Bolt(s), 826 Bonding: adhesive, 818–823, 918 atomic, 39–40 die (IC), 896 metallic, 40 molecular, 40–41 primary bonds, 39–40 secondary bonds, 40–41 wire, 896–897 Borax, 174 Borazon, 168 Boring, 554, 559–561 Boron, 174, 217 Boronizing, 717, 726 Boron nitride, 168 Bose-Einstein statistics, 899 Brass, 148, 151–152 Braze welding, 813 Brazing, 807–813 Brinell hardness, 68 Broaching, 579–580, 587–588 Bronze, 12, 148, 153 Buckyball, 948–949, 957 Buffing, 674 Built-up edge (machining), 532 Bulk deformation, 417, 429–474 Bulk micromachining, 938 Burnishing, 588 Burr, 482 Butadiene-acrylonitrile rubber, 206 Butadiene rubber, 204 Butyl rubber, 204 CAD/CAM, 985, 1023–1024 Calendering, 313, 367 Calipers, 99 Calorizing, 726 Capacity requirements planning, 1044, 1046 Capstan, 471 Carbide ceramics, 10, 166–167 Carbon: diamond, see Diamond fibers, 216–217 graphite, 172, 173 in cast iron, 139–141 in high speed steel, 138, 607–608 BINDEX.indd 1090 in steel, 124–125 nanostructures, 948–950 Carbon arc cutting, 695 Carbon arc technique, 957 Carbon arc welding, 775 Carbon black, 365 Carbon fullerenes, 948–949, 957 Carbon nanotubes, 949–950 Carbonitriding, 716, 726 Carburizing, 716, 726 Case hardening, 716 Cast cobalt alloy, 608 Cast iron, 10, 126, 139–141, 279–280 Casting: defined, 230–232 glass, 291 heating and pouring, 235–239 history, 231–232 metals, 279–281 molds, 233, 234–235 plastics, 338–339 processes, 233–234 product design considerations, quality, 277–279 rubber, 368 solidification and cooling, 239–246 Cellophane, 192 Cellular manufacturing, 21, 1011–1016 Cellulosics, 192 Cellulose acetate, 192 Cellulose acetate-butyrate, 192 Cemented carbide: cutting tools, 608–611 defined, 167, 222 processing of, 222–223, 411–413 Cementite, 126 Centerburst (extrusion), 467 Centering, 564 Centerless grinding, 668–669 Centrifugal atomization, 382 Centrifugal casting, 270–273, 289, 363 Centrifugal spraying (glass), 293 Centrifuge casting, 273 Ceramic matrix composites, 214, 224–225 Ceramic-mold casting, 263 Ceramic(s): classification of, 160 composites, 224–225 cutting tools, 612 defined, 10, 159 fibers, 217 hardness, 71, 165 glass, see Glass IC packaging, 897 new ceramics, 166–168, 408–411 processing of, 400–411 products, 160, 164–165, 166–168 properties, 49–50, 160–162 raw materials, 159, 163–164 traditional ceramics, 163–165, 401–408 Cermets: cutting tools, 608–609, 611 defined, 167, 222 processing of, 411–413 Chalcopyrite, 147 Chamfering, 554 Chaplet, 254 Chemical blanking, 700–701 Chemical cleaning, 722–724 Chemical conversion coating, 733 Chemical engraving, 701 Chemical machining, 696–702 Chemical milling, 699 Chemical vapor deposition: defined, 737–740 integrated circuits, 885–886, 887 microfabrication, 937 nanotube production, 957–958 Chill-roll extrusion, 312 China (ceramic), 165 China (country), 30–31 Chip(s): integrated circuit, 871 metal cutting, 528–532 Chip breaker, 614–615 Chip thickness ratio, 529 Chloroprene rubber, 205 Chromate coating, 733 Chromium, 134, 731 Chromium carbide, 167, 224 Chromizing, 716–717, 726 Chuck, 556–557 Chucking machine, 558 Chvorinov’s rule, 242, 245–246 Circuitization, 912–913 Circularity, 97 Clay, 10, 160, 163 Cleaning, 722–726, 921 Clean room, 873–874 Clearance: brazing, 809–810 sheet-metal drawing, 493 sheet-metal shearing, 484–485 Cleavage, 65 CMM, see Coordinate measuring machine CNC, see Numerical control Closed-die forging, 445 16/07/12 1:18 PM Index Coated carbides, 611 Coating(s): organic (paints), 740–743 plastics, 315–316 conversion, 732–734 rubber, 367–368 wire and cable, 309 Cobalt, 607, 608, 609–610 Cogging, 445 Coining, 389, 449, 501 Coke, 126 Cold extrusion, 459 Cold forming, 421 Cold rolling, 431 Cold welding, 791 Cold working, 421 Collet, 557 Comminution, 401 Composites: classification, 213, 214 components, 213–218 defined, 11, 212 processing, 348–364, 411–413 properties, 212–213, 218–221 rubber, see Elastomers Compound die, 504 Compression bending, 517 Compression molding, 327–328, 356–357 Compression properties, 62–64 Computer-aided design and manufacturing, 985, 1023–1024 Computer-aided process planning, 1035–1038 Computer integrated manufacturing, 1022–1024 Computerization of manufacturing, 28 Computer numerical control, see Numerical control Concentricity, 97 Concurrent engineering, 1039–1042 Conductivity (electrical), 90 Conductivity (thermal), 87 Connectors, electrical, 923–926 Contact lamination, 352 Contact molding, 352 Continuity law, 237 Continuous casting, 132 Continuous improvement, 1029, 1038, 1055 Continuous laminating, 363 Continuous path, 975 Contour turning, 549, 553, 559, 575 Contouring, 569, 574, 580, 975 Contract manufacturing, 30 BINDEX.indd 1091 Control chart(s), 1061–1066 Control resolution, 981–982 Control systems, 966–967 Conversion coating, 732–734 Coolants: grinding, 664–665 machining, 527, 623–626 Coordinate measuring machine, 1075–1076 Copolymers, 184–185 Copper, 147–148, 281, 731 Copper-nickel alloy system, 120–121 Core (casting), 234, 254 Corundum, 164 Cost analysis: automated production lines, 1011 equipment, 25 general, 23–27 machining, 642–645 rapid prototyping, 863–864 Cotter pin, 839 Counterboring, 564 Countersinking, 564 Covalent bond, 40 Crater wear, 597 Creep feed grinding, 669–670 Crimping, 841, 923 Cross-linking, 183, 188, 196–197, 203, 298 Cross-wire welding, 781 Crystalline structures: ceramics, 160–161 general, 41–44 polymers, 185–186 silicon, 875–879 Cubic boron nitride, 168, 613, 655 Cup drawing, 418 Cupola, 128, 273–274 Curing: adhesives, 818 organic coatings, 742 polymer composites, 356 polymers, see Cross-linking rubbers, see Vulcanization Curling, 492 Customization, mass, 28, 1020–1022 Cutoff, 486–487, 554, 580 Cutting: arc, 694–696 glass, 295 metal, see Machining oxyfuel, 696 polymer composites, 363–364 sheet metal, 482–488 Cutting conditions (machining): 1091 defined, 526 drilling, 562–563 grinding, 658–659 milling, 569–571 selection of, 639–645 turning, 552–553 Cutting fluid(s): grinding, 664–665 machining, 527, 623–626, Cutting force, see Forces Cutting speed: definition, 526 drilling, 562 grinding, 659 machining economics, 639–645 milling, 569 surface roughness, 638 tool life, 600–603 turning, 552 Cutting temperature, 540–542, 624 Cutting tool(s): basic types, 525–526 costs, 642–645 geometry, see Tool geometry grinding wheels, 654–658 history, 605 materials, 603–613 technology, 596–623 tool life, 596–603 Cycle time analysis: automated production lines, 1009–1011 general, 22–23 machining, 640–645 manual assembly lines, 1003–1006 rapid prototyping, 860–863 Cylindrical grinding, 667–668 Cylindricity, 97 Czochralski process, 875–877, 960 Danner process, 292 Dead center, 556 Deburring, 674, 682, 686, 724–725 Deckard, Carl, 855 Deep drawing, 418, 493–498 Deep grinding, 669 Defects: casting, 277–279 crystals, 43–44 drawing sheet metal, 500 extrusion (metal), 467 extrusion (plastic), 310 injection molding, 324 integrated circuits, 898–899 welding, 798–800 16/07/12 1:18 PM 1092 Index Deformation in crystals, 44–46 Deformation processes: bulk, 417, 429–474 defined, 15, 416 sheet metal, 417–418, 488–515 Densification, 389 Density, 84 Depth of cut: Chemical machining, 698–699 definition, 526 drilling, 562 grinding, 659 milling, 569 selection of, 639 turning, 552 Design considerations, see Product design considerations Design for assembly, 841–843, 1038–1039 Design for manufacturing, 1029, 1038–1039 Desktop machining, 849 Devitrification, 169 Dial indexing machine, 1008 Dial indicator, 102–103 Diamond: abrasive, 655 cutting tools, 612 properties, 173 structure, 40 Die(s): bar drawing, 472–473 extrusion (metal), 463–465 extrusion (plastic), 308–309 forging, 451–452 integrated circuits, 871 stamping, 481, 493, 503–505 threading, 582–583 Die bonding, 896 Die casting, 266–269 Die sinking, 569, 686, 690 Die swell, 77–78, 300–301 Dielectric, 91 Diffusion: defined, 88–90, 726–727 silicon processing, 872, 884, 937 heat treatment, 711, 717 Diffusion welding, 751, 792 Digital-to-analog converter, 970–971 Dimensions, 95, 96 Dimpling, 841 Dip casting, 368 Dip coating, 742 Dipole forces, 41 Dip-pen nanolithography, 959, 961 BINDEX.indd 1092 Direct digital manufacturing, 865 Direct extrusion, 457, 461 Disc grinder, 670 Divider, 99 Doctor blade, 315–316, 410 Doping, 727, 886 Draft: bar drawing, 469 casting, 282 forging, 451 plastic molding, 342 rolling, 432 Drain casting, 404 Draw bench, 471 Draw bending, 516–517 Drawing: bar, 417, 468–473 deep, 418, 493–498 glass, 292–294 plastic filaments, 315 sheet metal, 418, 493–500 wire, 417, 468–473 Drawing ratio, 496 Dressing (grinding), 663–664 Drill bit(s), 561 Drill jig, 565 Drill press(es), 564–565 Drilling, 16, 525, 555, 561–565, 910 Droplet deposition manufacturing, 857–858 Dry machining, 626 Dry plasma etching, 889–890, 937 Dry pressing, 406–407 Dry spinning, 315 Drying: ceramics, 407–408 organic coatings, 742 Dual in-line package, 895 Ductile iron, 141 Ductility, 56 Durometer, 70 EBM, see Electron beam machining ECM, see Electrochemical machining Edge bending, 489 Edging, 445 EDM, see Electric discharge machining Elastic limit, 55 Elastic modulus, see Modulus of elasticity Elastic reservoir molding, 357 Elastomers: defined, 10–11, 177, 200 history, 202, 204 important elastomers, 202–208 processing technology, 364–373 products, 369–373 properties, 11, 200–202 rubber production, 364–365 rubber shaping processes, 364, 366–368, 369–373 vulcanization, see Vulcanization Electric discharge forming, 515 Electric discharge machining, 687–690, 942 Electric discharge wire cutting, 690–692, 942 Electric furnaces: casting, 275 glassworking, 288, 294 heat treatment, 717 silicon processing, 875 steelmaking, 130 Electrical connectors, 923–926 Electrical properties, 90–92 Electrochemical deburring, 686 Electrochemical fabrication, 943 Electrochemical grinding, 686–687 Electrochemical machining, 93, 683–686 Electrochemical plating, 93, 728–731, 887, 911 Electroforming, 731, 937, 942 Electrogas welding, 772–773 Electrohydraulic forming, 515 Electroless plating, 731–732, 911, 937, 942 Electrolysis: aluminum production, 143 general, 92 magnesium production, 146 powder metals, 383 Electromagnetic forming, 515 Electron-beam heating, 718 Electron-beam lithography, 879, 883, 956 Electron-beam machining, 692, 942 Electron-beam welding, 787–788 Electronics packaging, see Packaging Electroplating, 93, 728–731, 887, 937, 942 Electroslag welding, 788–789 Elements, 37–39 Elongation (ductility), 56, 57 Embossing, 501 Encapsulation (plastic), 339 End effector, 989 16/07/12 1:18 PM Index Engine lathe, 555–556 Engineering materials, 9–11, 49–50 Engineering stress-strain, 54–57 Enterprise resource planning, 1024, 1049 Environmentally conscious manufacturing, 31 Epitaxial deposition, 886 Epoxies, 197–198, 896 Equipment, See Machine tools Etch factor, 699 Etching: chemical machining, 697–699 integrated circuits, 888–890 microfabrication, 937 printed circuit boards, 911 Ethylene-propylene rubber, 205 Eutectic alloy, 123, 241 Eutectic die bonding, 896 Eutectoid, 126 Evaporative-foam process, 259 Expandable foam molding, 340 Expanded polystyrene process, 259–260 Expansion fit, 836–837 Expendable mold casting, 257–263 Expert systems, 1037 Explosion welding, 792–793 Explosive forming, 514 Extreme UV lithography, 883 Extrusion: cemented carbides, 412 ceramics, 406 metals, 15, 417, 457–467 plastics, 301–312, 340 powder metals, 392 rubber, 367 Extrusion blow molding, 330–331 Eyelet(s), 833–834 Face-centered cubic (FCC), 42–43 Face plate, 557 Facilities, production, 19–21 Facing, 553 Faraday’s laws, 93, 684, 729 Fastener(s), 825–834, 838–841 Faying surfaces, 750 Feed (cutting): definition, 526 drilling, 562 electrochemical machining, 684 milling, 569 selection of, 640 surface roughness, 636–637 turning, 552 BINDEX.indd 1093 Feldspar, 164 Ferrite, 125, 711–712 Ferritic stainless steel, 136, 137 Ferrous metals, 10, 119, 124–141 Fiberglass, 160, 171, 173, 216 Fiber-reinforced composites, 219–221, 224, 225–227 Fiber-reinforced polymers: applications, 227 defined, 225 properties, 226–227 shaping processes, 348–364 Fibers: defined, 43, 165, 215 glass, 145–146, 293–294 in composites, 45–46, 215–217 materials, 46, 216–217 plastics, 165–166 production of, 293–294, 314–315 types, 44 Fick’s first law, 89 Filament, 215, 314 Filament winding, 349, 359–361 Film, plastic, 311–313 Finishing: ceramics, 411 gears, 588–589 glass, 295 machining, 527 powder metals, 390 printed circuit boards, 915 Firing (sintering), 163, 400, 408, 743 Fixture, 565, 752, 797 Flakes (composites), 217 Flame cutting, 696 Flame hardening, 718 Flanging, 492 Flank wear, 597 Flash: die casting, 268 forging, 445–446, 451 injection molding, 324 Flash welding, 781–782 Flashless forging, 441, 448–449 Flatness, 96, 97 Flexible manufacturing, 28 Flexible manufacturing system(s), 1016–1022 Flexible overlay process, 745 Flexure test, 65 Float process (glass), 292 Flow curve, 60, 419–421 Flow line production, 21 Flow stress, 419–421 Flow turning, 513 1093 Fluid properties: casting, 236–239 polymer melts, 299–301 viscosity, 73–75 Fluidity, 73, 238 Fluidized bed, 717, 743, 875 Fluoropolymers, 192–193 Flux: arc welding, 767 brazing, 810–811 oxyfuel welding, 784 soldering, 815–816 Flux-cored arc welding, 771–772 Fly cutter, 566 Foam: composite structure, 221 injection molding, 324–325 polymers, 185–186, 339–341 Foam injection molding, 324 Force(s): bar drawing, 470 bending sheet metal, 491 cutting sheet metal, 485–486 drawing sheet metal, 497 extrusion, 462–463 forging, 442–444, 446–447 grinding, 660–661 machining, 532–535 powder metals, 386 rolling, 434–436 stretch forming, 511 wire drawing, 470 Ford, Henry, Forge welding, 791 Forging: liquid-metal, 269 metals, 15, 417, 440–452 powder metals, 392 Forging hammer, 440, 449–451 Forging press, 440, 451 Form milling, 568, 585–586, 621 Form turning, 554 Forward extrusion, 457 Foundry, 233, 273 Fracture stress, 56 Free machining steel, 139, 635 Freezing point, 85 Friction: forging, 442, 446 metal cutting, 532, 624 metal extrusion, 460–461 metal forming, 425–426 rolling, 433–434 sheet metal drawing, 494 Friction sawing, 581 16/07/12 1:18 PM 1094 Index Friction stir welding, 795 Friction welding, 751, 793–795 Fullerene, 948–949, 957 Fullering, 445 Full-mold process, 259 Furnaces: basic oxygen, 129–130 blast furnace, 127–128 brazing, 812–813 casting, 273–276 electric, see Electric furnaces glassworking, 288, 294 heat treatment, 717 sintering, 388–389 Fused-deposition modeling, 856–857 Fusion welding, 750–751, 765–790 Gage blocks, 98–99 Gages and gaging, 98, 102–105, 1080 Galvanized steel, 151 Galvanizing, 732, 745 Gang drill, 565 Gas atomization, 382 Gas metal arc welding, 770–771 Gas tungsten arc welding, 774 Gear cutting, 584–589 Gear rolling, 439 Gear shaper, 578 Geometry: machined parts, 548–551 nontraditional processes, 703–704 powder metal parts, 394–396 tool, see Tool geometry Gilbert, W., 640 Glass: chemistry, 169 defined, 168 fibers, 216 history, 168–169 product design, 295 products, 169–171 properties, 169 shaping processes, 288–294 Glass-ceramics, 171–172 Glass transition temperature, 49 Glassworking, 287–295 Glazing, 164, 408 Globalization, 29–31 Gold, 154 Graphite, 173 Grains and grain boundaries, 47 Grain size (abrasives), 655, 679 Gray cast iron, 140, 141 Green manufacturing, 31 BINDEX.indd 1094 Grinding, 16, 402–403, 588–589, 653–671 Grinding fluids, 664–665 Grinding ratio, 663 Grinding wheels, 654–658 Gross domestic product, Group technology, 1011, 1015–1016 Guerin process, 502–503 Gun drill, 619–620 Hacksaw, 580 Hand lay-up, 353–354 Hand modeling (clay), 405 Hard facing, 744 Hardenability, 714 Hardness: abrasives, 655 cutting tool materials, 604, 607–613 defined, 67 of materials, 70–71 tests, 67–70 Heading, 453 Heat-affected zone, 760–761 Heat of fusion, 48, 85, 235, 239 Heat treatment: castings, 277 ceramics, 408, 411 cermets, 412–413 glass, 294–295 metals, 709–719 powder metals, 390 processes, 709–719 Hematite, 126 Hemimorphate, 151 Hemming, 492 Hexagonal closed-packed (HCP), 42–43 High-energy-rate forming, 514–515 High speed machining, 589–590 High speed steel, 138, 607 High strength low-alloy steel, 135 Historical notes: abrasive processes, 654 additive manufacturing, 848–849 adhesive bonding, 818 aluminum, 143 casting, 231–232 cast iron products, 280 ceramics, 163 copper, 147 cutting tool materials, 605 die casting, 266 extrusion (metal), 457 forging, 440 glass, 291 integrated circuits, 870 investment casting, 260–262 iron and steel, 124–125 lean production, 1052–1053 machine tools, 549 manufacturing processes, 12–13 manufacturing systems, 2–3 measurement systems, 97–98 numerical control, 973 plastic shaping processes, 298 polymers, 177 powder metallurgy, 377 printed circuit boards, 907 rapid prototyping, 848–849 rolling, 431 rubber, 202, 204 surface mount technology, 916 tungsten carbide, 167 welding, 749–750 Hobbing, gear, 586 Honeycomb composite structure, 221 Honing, 589, 672 Hooke’s Law, 55, 58 Hot-die forging, 456 Hot dipping, 732 Hot extrusion, 459 Hot forming, 422 Hot hardness, 72, 604–605 Hot pressing, 392, 410, 412 Hot pressure welding, 791 Hot rolling, 430 Hot working, 73, 422 Hubbing, 455 Hybrid composite, 226 Hydroforming, 503 Hydrogen bonding, 41 Hydrostatic extrusion, 466–467 Ilmenite, 149, 167 Impact extrusion, 459, 465 Impact grinding, 403 Impregnation (powder metals), 389 Impression-die forging, 440–441, 445–448 Incremental positioning, 975 Indirect extrusion, 458, 461 Induction heating, 275–276, 718 Industrial Revolution, Industrial robotics, 986–992 Industries, 5–6 Infeed, 659 Infiltration (powder metals), 389–390 Injection blow molding, 331–332 Injection molding, 316–326, 357, 358 Inserts: 16/07/12 1:18 PM Index cutting tool, 616–617 molding, 839 screw thread, 828–829 Inspection: casting, 279 defined, 1072 electronic assemblies, 921–922 instruments and gages, 97–106 integrated circuits, 897, 899 machine vision, 1080 principles, 1072–1075 printed circuit boards, 915 robotic, 992 surfaces, 112–114 technologies, 1075–1081 welding, 799–800 Insulators, 90 Integral fasteners, 839–841 Integrated circuit processing, 869–899 Integrated manufacturing systems, 997–1024 Interchangeable parts, Interference fit(s), 834–838 Intermediate phase, 120 Interphase (composites), 218 Interpolation, 975 Interstitial free steel, 139 Inverse lever rule, 122–123 Investment casting, 260–261 Ion implantation, 727–728, 886, 937 Ion beam lithography, 879, 883 Ionic bond, 40 Ion plating, 736–737 Iridium, 154–155 Iron, 124 Iron-carbon alloy system, 125–126 Ironing, 32, 500–501 Iron ores, 126 ISO 9000, 1072 Isoprene rubber, 205 Isostatic pressing, 390, 410, 412 Isothermal extrusion, 459 Isothermal forging, 455–456 Isothermal forming, 422–423 Jig, 565 Jig grinder, 670 Jiggering, 405 Job shop, 19–20, 1042 Joining, 17, 748, 807 Joint(s): adhesive bonded, 819–820 bolted, 826, 829–831 BINDEX.indd 1095 brazed, 808–810 soldered, 814 weld, 753–755 Jolleying, 405 Jominy end-quench test, 714 Just-in-time, 1049–1052 Kanban, 1051 Kaolinite, 159, 163 Kernite, 174 Kevlar, 193, 217 Kiln, 408 Knoop hardness, 69 Knurling, 555 Kroll process, 150 Ladles (casting), 276 Laminated-object manufacturing, 858–860 Lancing, 501 Lapping, 589, 673 Laser-beam heating, 718 Laser-beam machining, 693–694, 942 Laser-beam welding, 788 Laser evaporation method, 957 Laser measurement, 1077–1078 Lathe(s), 555–559 Lead, 152 Leadthrough programming, 990 Lean production, 29, 1052–1056 Lehr, 294 Lift-off technique, 939 LIGA process, 939–940 Limestone, 127 Limit dimensions, 96 Limonite, 126 Line balancing, 1004–1006, 1034 Liquid-metal forging, 269 Liquid phase sintering, 393, 412 Liquidus, 85, 236, 240 Lithography, 872, 879–883, 937 Live center, 556 London forces, 41 Lost-foam process, 259 Lost pattern process, 259 Lost-wax process, 260 Low-pressure casting, 265 Lubricants and lubrication: ceramics, 409 drawing sheet metal, 495, 500 grinding, 664–665 metal cutting, 527, 624–625 metal forming, 425–426 plastics, 188 powder metals, 384 1095 Machinability, 632–635 Machine cell(s), 1013–1015 Machine tools: cost rate, 25 defined, 17–18 die casting, 267–268 drilling, 564–565 forging, 449–451 grinding, 665–671 machining, 527–528 machining centers, 574–576 milling, 571–574 plastic extrusion, 301–303 plastic molding, 321 presses, see Presses turning and boring, 555–561 wire and bar drawing, 471–472 Machine vision, 1078–1080 Machine welding, 752 Machining: advantages and disadvantages, 524, 548 defined, 15, 522–523 economic considerations, 632–645 machine tools, see Machine tools part geometry, 548–551 powder metallurgy, 389 processes, 15–16, 524–525, 552–590 product design considerations, 646–647 theory, 528–541 tooling, see Cutting tools Machining center, 574–575 Machining economics, 640–645 Magnesium, 145–146, 281 Magnetic pulse forming, 515 Magnetite, 126 Make or buy decision, 1034–1035 Malleable iron, 141 Mandrel, 361, 474 Manganese, 134 Mannesmann process, 440 Manual assembly line(s), 1002–1006 Manual data input, 60, 985–986 Manufactured products, Manufacturing, defined, 2, 4–5 Manufacturing capability, 7–8 Manufacturing economics: additive manufacturing, 860–864 automated production lines, 1011 equipment cost rate, 25 general, 22–27 machining, 640–645 rapid prototyping, 860–864 16/07/12 1:18 PM 1096 Index Manufacturing engineering, 22, 1029 1042 Manufacturing, history, 2–3, 12–13 Manufacturing industries, 5–6 Manufacturing processes, classification of, 11–17 Manufacturing resource planning, 1049 Manufacturing support systems, 18–19, 21–22, 1028 Manufacturing system(s), 2, 19, 964–965, 997–1024 Maraging steel, 139, 714 Martensite, 134, 141, 155, 710–714 Martensitic stainless steel, 137 Masks and masking, 697, 879, 882 Mass customization, 28, 1020–1022 Mass diffusion, 88–90 Mass finishing, 725–726 Mass production, 21, 1042 Master production schedule, 1043 Material handling: general, 997–999 production lines, 1000–1001 robotic, 991 Material removal processes, 15–16, 522, 849 Material requirements planning, 1044–1045 Materials, engineering, see Engineering materials Materials in manufacturing, 9–11 Measurement: conventional instruments, 99–103, 105–106 cutting temperatures, defined, 97–98 history, 97–98 lasers, 1077–1078 machine vision, 1080 surfaces, 112–114 Mechanical assembly, 825–843 Mechanical cleaning, 724–726 Mechanical plating, 745 Mechanical properties, 52–78 Mechanical thermoforming, 337–338 Melamine formaldehyde, 197 Melt fracture, 310 Melt spinning, 314–315 Melting point, 84, 85–86 MEMS, 928 Merchant equation, 535–537 Mesh count, 378 Metal cutting, see Machining Metal forming, 416–426 Metal injection molding, 391 BINDEX.indd 1096 Metallic bonding, 40 Metallization, 887 Metalloids, 37 Metal matrix composites, 214, 222–224 Metals, 9–10, 49, 118–156 Metal spraying, 744 Metalworking: bulk deformation, 417, 429–474 machining, see Machining sheet, see Sheet metalworking Micro-contact printing, 942 Microelectromechanical systems, 928 Microelectronics: trend, 27–28 integrated circuits, 27, 869–899 packaging, 904–926 Microfabrication, 28, 928–943 Micro-imprint lithography, 941, 956 Micromachining, 938 Micrometer, 101–102 Microscopes, 953–955 Microsensors, 929 Microstereolithography, 943 Microsystems, 928, 929 MIG welding, 770 Milling, 16, 525, 566–574 Milling cutters, 566, 620–622 Milling machine(s), 571–574 Mill-turn center, 576 Modulus of elasticity, 55 Mold(s): casting, 233–234, 254–273 plastic injection, 319–320 polymer matrix composites, 352, 354 thermoforming, 335–336 Molding: blow, 329–333 ceramics, 404–407, 410 compression, 327–328 injection, 316–326 polymer matrix composites, 353–358 rotational, 333–334 rubber, 368, 373 tires, 372 transfer, 328 Molding inserts, 839 Molecular-beam epitaxy, 886 Molecular manufacturing, 947 Molybdenite, 153 Molybdenum, 134, 153–154, 607, 608, 611 Mond process, 738 Monolayer, 961 Moore’s law, 869 Multifunction machine, 576 Multi-injection molding, 325 Multitasking machine, 576 Multiprobe, 896 Mushy zone, 240–241 Nanofabrication processes, 955–962 Nano-imprint lithography, 956 Nanorobots, 947 Nanoscience, 945, 951–955 Nanotechnology, 28–29, 928, 945–962 Nanotubes, 949–950 National Nanotechnology Initiative, 950–951 Natural rubber, 202–203, 364–365 Natural tolerance limits, 1060 NC, see Numerical control Near net shape, 16, 232, 376, 429, 448 Necking, 53, 56, 61 Neoprene, 205 Net shape, 16, 232, 297, 376, 429, 448 Newtonian fluid, 74, 299 Nickel, 134, 148–149, 611, 730 Nitride ceramics, 10, 167–168 Nitriding, 716, 726 Nitrile rubber, 206 Noble metals, 38, 154 Noncrystalline structures, 47–49 Nonferrous metals, 10, 119, 142–155 Nontraditional processes, 16, 522, 678–704 Normalizing, 710 Notching, 487 Numerical control: applications, 986 definition, 973 drilling, 565 filament winding, 360 history, 973 machining center, 574–576 milling, 574 part programming, 984–986 punch press, 508 tape-laying, 355 technology, 973–986 turning, 559 Nut(s), 826 Nylon, 193 Open-back inclinable, 506 Open-die forging, 440, 441–445 Open mold, 233, 352–356 Operation sheet, 1033 16/07/12 1:18 PM Index Optical encoder, 979 Orbital forging, 455 Organic coating, 740–743 Orthogonal cutting, 528–530, 535, 537 Osmium, 154–155 Outsourcing, 29–30 Overhead cost, 24 Oxide ceramics, 166 Oxyacetylene welding, 783–785 Oxyfuel cutting, 696 Oxyfuel welding, 751, 783–787 Packaging, electronics: defined, 892, 902–906 electrical connectors, 923–926 integrated circuit, 892–897 printed circuit board assembly, 904–921 Packing factor (powders), 381 Painting, 721, 722, 723, 733, 740–742 Palladium, 154 Parallelism, 96, 97 Parison, 290, 329, 332 Part family, 1011 Part geometry (machining), 548–551 Part programming, NC, 974, 984–986 Particles (in composites), 217 Particulate processing, 14–15, 375 Parting, 487 Parts classification and coding, 1012–1013 Pattern (casting), 234, 244, 252–254, 261 Pearlite, 711 Pentlandite, 148 Percussion welding, 782 Perforating, 487 Permanent mold casting, 263–273 Perpendicularity, 97 Phase: defined, 11, 119 determining composition, 121–122 in composites, 213–218 Phase diagrams: copper-nickel, 120–123 defined, 120 iron-carbon, 125–126 tin-lead, 123–124 WC-Co, 413 Phenol-formaldehyde, 198 Phenolics, 198 Phosphate coating, 733 Photochemical machining, 701–702, 942 Photofabrication, 943 BINDEX.indd 1097 Photolithography, 879, 911 Photoresist, 697, 880, 881 Physical properties, 83–93 Physical vapor deposition, 734–737, 937 Pig iron, 128 Pin grid array, 895 Pin-in-hole technology, 894, 905 Piping (extrusion), 467 Planing, 578 Plant capacity, 8, 1046 Plant layout, 19–21 Plasma arc cutting, 694–695 Plasma arc welding, 774–775 Plasma etching, 889 Plaster-mold casting, 263 Plastic deformation, 44–46, 419–425, 599 Plastic forming, 405–406 Plasticizers, 177, 187, 188, 195 Plastic pressing, 406 Plastics, see Polymers Plating processes, 728–732 Platinum, 154–155 Pointing (bar drawing), 473 Point-to-point, 975, 976, 978, 984, 985, 990 Polishing, 674 Polyamides, 193 Polybutadiene, 204 Polycarbonate, 193 Polychloroprene, 205 Polydimethylsiloxane, 206 Polyester, 194, 198–199, 207 Polyethylene, 194 Polyethylene terephthalate, 194 Polyimide, 199 Polyisoprene, 205 Polymerization, 179–181, 961 Polymer matrix composites: defined, 214, 225–227 fiber-reinforced, see Fiberreinforced polymers molding compounds, 351–352 shaping processes, 349–364 Polymer melt, 299–301 Polymers: additives, 187–188 biodegradable, 209–210 classification of, 10–11, 176–177, 298 composites, see Polymer matrix composites defined, 10–11, 176 history, 177, 298 IC packaging, 897 1097 properties, 50, 71, 189–190 recycling, 208–209 rubbers, see Elastomers science, 178–188 shaping processes, 297–341 structures, 182–186 thermal behavior, 186–187 thermoplastics, see Thermoplastic polymers thermosets, see Thermosetting polymers Polymethylmethacrylate, 191 Polyoxymethylene, 191 Polypropylene, 195 Polystyrene, 195, 340 Polytetrafluoroethylene, 192 Polyurethane, 199, 206, 207, 340 Polyvinylchloride, 195–196 Porcelain, 165, 743 Porcelain enameling, 743 Porosity (metal powders), 381 Positioning systems, 975–983 Potter’s wheel, 405 Powder bed fusion, 854 Powder coating, 742–743 Powder injection molding, 391, 410–411 Powder metallurgy, 375–396 Powders, 377–381, 393–394 Power: arc welding, 767–768 automation, 965–966 electron-beam welding, 787 extrusion, 462 machining, 538–540 resistance welding, 776–777 rolling, 435–436 Power density (welding), 756–757 Precious metals, 154–155 Precipitation hardening, 137, 714–716 Precision, defined, 98 Precision forging, 447, 449 Precision gage blocks, 98–99 Preform molding, 357 Prepreg, 352, 353, 359 Press(es): drill, 564–565 extrusion (metal), 465 forging, 451 powder metallurgy, 386, 387 stamping, 481, 505–510 Press-and-blow, 289–290 Press brake, 506 Press fit, 834–836, 924 16/07/12 1:18 PM 1098 Index Pressing: cemented carbides, 412 ceramics, 406–407, 410 glass, 289 powder metallurgy, 375, 385–386, 392–393 Pressure gas welding, 786–787 Pressure thermoforming, 335–337 Pressworking, 417 Primary bonds, 39–40 Printed circuit board, 906–915 Printed circuit board assembly, 915–923 Process capability, 1059–1061 Process controller(s), 971–973, 974 Process planning, 1029–1038 Processing operations, 11 Processes, manufacturing, 11–17 Product design considerations: assembly, 841–843 casting, 281–283 ceramics, 413–414 design for manufacturing, 1038–1039 glass, 295 machining, 646–647 plastics, 341–343 powder metallurgy, 394–396 welding, 801–802 Product variety, 7, 1001–1002 Products, manufactured, Production capacity, Production flow analysis, 1012 Production line(s), 21, 1000–1002, 1006–1009 Production machines, see Machine tools Production planning and control, 22, 1042–1049, 1051 Production quantity, 6–7, 19–21 Production systems, 2–3, 18–22, 964 Programmable logic controller, 972–973 Progressive die, 505 Properties: fluid, see Fluid properties mechanical, see Mechanical properties physical, see Physical properties thermal, see Thermal properties Property-enhancing processes, 16, 709 Protractor, 105–106 Pseudoplastic, 75, 299 Pulforming, 362 BINDEX.indd 1098 Pultrusion, 349, 361–362 Punch-and-die, 418, 481, 503–505 Punching, 483 Quality: casting, 277–279 defined, 1058–1059 design for, 1041 metal extrusion, 467 plastic extrusion, 310 plastic injection molding, 324 programs, 1066–1072 weld, 796–800 Quality control, 22, 1058–1072 Quantity, production, 6–7, 19–21 Quantum mechanics, 953 Quartz, 163, 875 Quenching, 713 Radial drill, 565 Radial forging, 454 Rake angle, 525–526, 529, 614 Rapid prototyping, 847–865 Rapid tool making, 864 Reaction injection molding, 326, 341, 358 Reaming, 564 Recrystallization, 72–73, 710 Recrystallization temperature, 72–73 Recycling, 208–209, 288 Redrawing, 498 Reduction: bar drawing, 468 drawing sheet metal, 496 extrusion, 460 rolling, 432 shear spinning, 513 Reflow soldering, 817–818, 917–918 Refractory ceramics, 160, 165 Refractory metals, 153–154 Reinforcing agents, in composites, 213, 215–217 in plastics, 188 Relief angle, 526, 614 Rent’s rule, 893–894 Repeatability, 983 Resin transfer molding, 357 Resist, 697–698, 880–882 Resistance projection welding, 781 Resistance welding, 751, 776–782 Resistivity, 90, 91 Retaining ring, 838 Reverse drawing, 498 Reverse extrusion, 458 Rheocasting, 270 Rhodium, 154 Ring rolling, 438–439 Riser (casting), 235, 245–246 Rivet(s), 833–834 Robotic welding, 752 Robots (industrial), see Industrial robotics Robust design, 1072 Rockwell hardness, 68–69 Roll bending, 511, 517 Roll coating, 823 Roll forging, 454 Roll forming, 511–512 Roll piercing, 439–440 Roll straightening, 511 Roll welding, 791 Roller mill, 402 Rolling: gear, 439 glass, 291–292 metals, 417, 430–438 powder metals, 392 ring, 438–439 thread, 438 Rolling mills, 436–438 Rotary tube piercing, 440 Rotational molding, 328, 333–334 Rotomolding, 333 Roughing (machining), 527 Roughness, see Surface roughness Roundness, 96, 97 Route sheet, 1032–1033 Rubber, see Elastomers Rule, steel, 99 Rule of mixtures, 219 Ruthenium, 154 Rutile, 149, 167 Sand blasting, 724 Sand casting, 234–235, 245, 251–257 Sandwich molding, 325, 340 Sandwich structure, 221 Saw blade, 622–623 Sawing, 580–581 Scanning probe microscopes, 953–955, 958–959 Scanning laser systems, 1077 Scanning tunneling microscope, 934, 954, 958 Scheduling, order, 1048 Scheelite, 153 Scientific management, Scleroscope, 69–70 Scrap rate, 26 Screen printing, 910 16/07/12 1:18 PM Index Screen resist, 697 Screw(s), 826–828 Screw threads, 581–584 Screw thread inserts, 828–829 Seam welding, 779–780 Seaming, 492, 841 Secondary bonds, 40–41 Segregation (in alloys), 122 Selective laser sintering, 854–855 Self-assembly, 960–962 Semicentrifugal casting, 272 Semiconductor, 91 Semi-dry pressing, 406 Semimetals, 37 Seminotching, 487 Semipermanent-mold casting, 264 Semisolid metal casting, 270 Sensors, 929, 968–969 Setup reduction, 647, 1050 Sewing, 838–839 Shape factor: extrusion (metal), 464 extrusion (plastic), 306 forging, 443, 446 Shape rolling, 436 Shaping, 577–578, 586–587 Shaping processes, 14–16 Sharkskin, 310 Shaving, 488 Shear angle, 486, 528–530, 535 Shear forming, 513 Shear modulus, 67 Shear plane, 528 Shear properties, 65–67 Shear spinning, 513–514 Shear strength: defined, 67 metal machining, 535 sheet metal cutting, 485–486 Shearing, 418, 482, 483 Sheet: metal, defined, 481 metalworking, 15, 417–418, 481–515 plastic, 311–313 Shell casting, 339 Shell molding, 257–258 Shielded metal arc welding, 768–770 Shop floor control, 1046–1048 Shot peening, 724 Shrink fit, 836–837 Shrinkage: casting, 243–244 ceramics, 403, 405, 406, 407, 408, 414 cermets, 412 BINDEX.indd 1099 plastic molding, 322–323 powder metals, 380, 387, 390, 391 Sialon, 168, 612 Siderite, 126 Silica, 10, 159, 163, 169 Silicon: element, 174 integrated circuit processing, 872, 874–879, 885 microfabrication processes, 935–939 Silicon carbide, 10, 164, 165, 655, 679, 725 Silicon nitride, 167 Silicones, 200, 206 Siliconizing, 727 Silk screening, 697, 822 Silver, 154 Simultaneous engineering, 1040 Sine bar, 106 Single-point tool(s), 526 Sintered carbides, see Cemented carbide Sintered polycrystalline diamond, 612, 655 Sintering: cemented carbides, 412–413 ceramics, 408, 411 cermets, 412–413 liquid phase, 393, 412 metal powders, 375, 386–389, 392–393 porcelain enameling, 743 Six Sigma, 29, 1067–1069 Size effect, 539, 660 Slab, 430 Slide caliper, 100 Slip, deformation, 45 Slip casting, 404–405 Slit-die extrusion, 311–312 Slotting, 568, 580 Slush casting, 265, 339 Smithsonite, 151 Snag grinder, 670 Snap fit, 837, 843 Snap ring, 838 Soaking (heat treatment), 430, 710 Soft lithography, 941–941 Solder paste, 817, 917–918 Soldering, 814–818, 920 Solid ground curing, 848, 854f Solid solution, 119–120 Solid-state electronics, 869 Solid-state welding, 765, 790–796 Solidification processes: defined, 14, 230 1099 glassworking, 287–294 metal casting, 230–246, 251–273 plastics, 297–343 polymer-matrix composites, 349–363 rubber, 364–373 Solidification time (casting), 239–241, 242, 245–246 Solidus, 85, 236, 240 Spade drill, 620 Spark sintering, 393 Specific energy: grinding, 660–661 machining, 538 Specific gravity, 84 Specific heat: casting, 235–236 defined, 87 machining, 541 Speed lathe, 558 Sphalerite, 151 Spin forging, 513 Spinning: glass, 289 plastics, 314–315 sheet metal, 512–514 Spot facing, 564 Spot welding, 755, 778–779 Spraying (coating), 316, 368, 822 Spray-up, 354–355 Springback, 490 Sputtering, 736, 887 Squareness, 97 Squeeze casting, 269 Stainless steel, 135–137 Stamping, 418, 481, 503 Stapling, 838 Statistical process control, 1061–1066 Steel(s): defined, 10, 126, 133 for casting, 280–281 heat treatment, 710–714 high speed, see High speed steel low alloy, 134–135 plain carbon, 133–134 production of, 126–132 specialty, 139 stainless, 135–137 tool, 138–139 Stepping motor, 644–646 Stereolithography, 590–591, 611, 852–854, 943 Stick welding, 768 Sticking (friction), 259, 264, 425, 433 Stitching, 838 Straightness, 97 16/07/12 1:18 PM 1100 Index Strain: defined, 54, 58 forging, 441 machining, 529–530 metal extrusion, 460 rolling, 433 shear spinning, 513 sheet-metal bending, 488 sheet-metal drawing, 494, 498 wire and bar drawing, 469 Strain hardening, 55, 59–61 Strain hardening exponent, 60, 419 Strain-rate, 423 Strain-rate sensitivity, 423–425 Strand casting, 132 Strength coefficient, 60, 419 Strength-to-weight ratio, 84 Stress-strain relationship: compression, 62–64 metal forming, 419–421 shear, 65–67 tensile, 53–61 types of, 61–62 Stretch bending, 516 Stretch blow molding, 332 Stretch forming, 510–511 Structural foam molding, 324, 340 Stud (fastener), 828 Stud welding, 775–776 Styrene-butadiene rubber, 207 Styrene-butadiene-styrene, 207 Submerged arc welding, 773 Super alloys, 155–156 Superconductor, 91 Supercooled liquid, 49, 85 Superfinishing, 673–674 Superheat, 236 Surface finish, see Surface roughness Surface grinding, 665–666 Surface hardening, 716–717, 718 Surface integrity, 111–112, 113–114 Surface micromachining, 938 Surface-mount technology, 894, 904, 915–918 Surface plate, 99 Surface processing, 16, 721–745 Surface roughness: abrasive processes, 671 casting, 282 defined, 109–110 grinding, 659–660 machining, 636–639 manufacturing processes, 114–115 measurement of, 112–113 BINDEX.indd 1100 Surface technology, 107 Surface texture, 107, 108–110 Surfaces, 95, 106–110 Surfacing weld, 755 Sustainable manufacturing, 31 Swaging, 453–454 Swell ratio (polymers), 301 Synthetic rubber, 203–208, 365 Systems, production, 2–3, 18–22, 964 Tack welding, 797–798 Taguchi methods, 1070–1072 Tantalum carbide, 166, 610 Tape-laying machines, 355 Taper turning, 553 Tapping, 564, 584 Taylor, Frederick, 3, 600, 605 Taylor tool life equation, 599–603 Technological processing capability, Technology (defined), Teflon, 192 Temperature: effect on properties, 71–73 grinding, 661–662 machining, 540–542, 624 metal forming, 421–423 strain rate sensitivity, 424–425 Tempering: glass, 294 steel, 713 Tensile strength, 55–56, 70–71, 486, 497 Tensile test, 53–62 Terneplate, 732 Testing: bending, 65 compression, 62–63 defined, 1072–1073 electronic assemblies, 922 hardness, 67–70 integrated circuits, 897 printed circuit boards, 915 tensile, 53–62 torsion, 66 welds, 799–800 Thermal energy processes, 687–696 Thermal oxidation, 884–885, 937 Thermal properties: conductivity, 87 diffusivity, 88 expansion, 48, 84–85, 836 in casting, 235–236 in machining, 541 in manufacturing, 85, 88 in plastics shaping, 299–300 specific heat, 87 Thermal spraying, 744 Thermit welding, 789–790 Thermocompression bonding, 897 Thermoforming, 334–338, 340 Thermoplastic elastomers, 207–208, 369 Thermoplastic polymers: composites, see Polymer matrix composites defined, 10–11, 176 elastomers, 207–208, 369 important thermoplastics, 190–196 properties, 50, 189–190 shaping processes, 297–341 Thermosetting polymers: composites, see Polymer matrix composites defined, 10–11, 176–177 important thermosets, 197–200 properties, 50, 196–197 shaping processes, 297–341 Thermosonic bonding, 897 Thin-film magnetic heads, 931–932 Thixocasting, 270 Thixomolding, 270 Threaded fasteners, 826–832 Thread cutting, 554, 582–584 Thread rolling, 438 Three-dimensional printing, 855 Through hole (drilling), 562 Through-hole technology, 894, 905, 919–923 TIG welding, 774 Time-temperature-transformation curve, 711–712 Time, machining: drilling, 562 electrochemical machining, 684–685 milling, 570 minimizing, 640–642 turning, 553 Tin, 152–153, 281, 731 Tin-lead alloy system, 123–124 Tinning, 732, 814 Tires, 369–373 Titanium, 149–150 Titanium carbide, 167, 223, 610, 611 Titanium nitride, 168, 611 Tolerance(s): casting, 282, 283 defined, 95, 96 16/07/12 1:18 PM Index machining, 635–636 manufacturing processes, 114–115 natural tolerance limits, 1060 plastic molding, 342–343 Tool-chip thermocouple, 541 Tool geometry: broach, 622 drill, 618–620 effect on surface roughness, 636–637 effect of tool material, 615–616 milling cutter, 620–622 multiple-cutting edge, 526, 618–623 orthogonal cutting, 528 saw blade, 622–623 single-point, 526, 614–617 twist drill, 618–619 Tool grinders, 670 Tooling, general, 18 Tool life (machining), 559–603 Tool, machine, see Machine tool Tool steels, 138–139 Tool wear (machining), 597–599 Tools, see Cutting tools and Dies Torsion test, 66 Total productive maintenance, 1054–1055 Total quality management, 1066 Total solidification time, 239–241, 242, 245–246 Transfer line, 1007–1008 Transfer molding, 328, 357–360 Transverse rupture strength, 65, 609 Trimming, 276, 456 True stress-strain, 58–62 Truing (grinding), 664 TTT curve, 711–712 Tube bending, 516–517 Tube drawing, 473–474 Tube rolling, 363 Tube sinking, 473 Tube spinning, 514 Tumbling, 725 Tungsten, 153–154, 607, 608 Tungsten carbide: cutting tools, 223 general, 167, 223 history, 167 processing of, 411–413 Tunneling, 954 Turning, 15, 525, 536–537, 552–561, 575–576 Turning center, 575–576 Turret drill, 565 BINDEX.indd 1101 Turret lathe, 558, 561 Turret press, 508 Twinning, 46 Twist drill, 618–619 Twisting, 502 Two-roll mill, 366 Ultimate tensile strength, 55–56, 70–71, 486, 497 Ultra-high precision machining, 942 Ultrasonic bonding, 897 Ultrasonic inspection, 1081 Ultrasonic machining, 679–680, 942 Ultrasonic welding, 751, 796 Ultraviolet, 880, 883 Undercut, 699 Unilateral tolerance, 96 Unit cell, 42 Unit operation, 11 Unit energy (welding), 757 Unit power (machining), 538 Upset forging, 441, 452 Upset welding, 782 Upsetting, 441, 452 Urea formaldehyde, 197 V-bending, 489 V-process, 258 Vacuum evaporation, 734–735, 887 Vacuum forming, 334 Vacuum molding, 258–259 Vacuum permanent-mold casting, 265 Vacuum thermoforming, 334–335 Van der Waals forces, 41, 954 Vanadium, 134 Vapor degreasing, 723 Vapor deposition processes, 734–740 Vapor-phase epitaxy, 886 Vernier caliper, 101 Vibration, machining, 639 Vibratory finishing, 725 Vickers hardness, 69 Viscoelasticity, 76–78, 300–301 Viscosity, 73–75, 299–300 Vision, machine, 1078–1080 Visual management, 1055 Vitreous, 163 Volumetric specific heat, see Specific heat Vulcanization, 201, 203, 368–369 1101 Washer, 829 Water atomization, 382 Water jet cutting, 680–681 Wave soldering, 817, 918 Waviness (surface texture), 108 Wear: cutting tool, 597–599 grinding wheel, 662–664 Weldability, 800–801 Weldbonding, 819 Weld joints, 753–755, 760–761 Welding: defects, 798–799 definition and overview, 748–753 design considerations, 801–802 history, 749–750 joints, 753–755, 760–761 physics, 755–759 processes, 750–751, 765–796 quality, 796–800 Wet chemical etching, 888–889 Wet lay-up, 353 Wet spinning, 315 White cast iron, 140, 141 Whitney, Eli, WIG welding, 774 Wire and cable coating, 309 Wire bonding, 896–897 Wire drawing, 468–473 Wire EDM, 690, 942 Wolframite, 167 Work content time, 1003 Work hardening, 59 Work holding: boring, 559–560 drilling, 565 turning, 556–557 Wrought metal, 119 X-ray inspection, 1081 X-ray lithography, 879, 883, 956 Yield point, 55 Yields, 898 Yield strength, 55, 497 Young’s modulus, 55 Zinc, 151–152, 730, 732 Wafer, silicon, 877–879, 896, 898 Warm working, 421–422 16/07/12 1:18 PM BINDEX.indd 1102 16/07/12 1:18 PM STANDARD UNITS USED IN THIS BOOK Units for both the System International (SI, metric) and United States Customary System (USCS) are listed in equations and tables throughout this textbook Metric units are listed as the primary units and USCS units are given in parentheses PREFIXES FOR SI UNITS: Prefix Symbol nano- n Multiplier 10 Example units (and symbols) Ϫ9 nanometer (nm) Ϫ6 micro- m 10 micrometer, micron (mm) milli- m 10Ϫ3 millimeter (mm) centi- c deci- d 10 Ϫ2 centimeter (cm) 10 Ϫ1 decimeter (dm) kilo- k 10 kilometer (km) mega- M 106 megaPascal (MPa) G giga- 10 gigaPascal (GPa) TABLE OF EQUIVALENCIES BETWEEN USCS AND SI UNITS: Variable SI units USCS units Equivalencies Length meter (m) inch (in) 1.0 in ϭ 25.4 mm ϭ 0.0254 m foot (ft) 1.0 ft ϭ 12.0 in ϭ 0.3048 m ϭ 304.8 mm yard 1.0 yard ϭ 3.0 ft ϭ 0.9144 m ϭ 914.4 mm mile 1.0 mile ϭ 5280 ft ϭ 1609.34 m ϭ 1.60934 km micro-inch (m-in) Area 2 2 in , ft 3 3 m , mm 1.0 m-in ϭ 1.0 ϫ 10Ϫ6 in ϭ 25.4 ϫ 10Ϫ3 mm 1.0 in2 ϭ 645.16 mm2 1.0 ft2 ϭ 144 in2 ϭ 92.90 ϫ 10Ϫ3 m2 Volume m , mm 1.0 in3 ϭ 16,387 mm3 in , ft 1.0 ft3 ϭ 1728 in3 ϭ 2.8317 ϫ 10Ϫ2 m3 Liquid measure liter (L) gallon, quart, in 1.0 gallon ϭ 4.0 quarts ϭ 231 in3 ϭ 3.785 L 1.0 quart ϭ 2.0 pints ϭ 4.0 cups ϭ 32 fl oz ϭ 0.946 L (1.0 L ϭ 10Ϫ3 m3 ϭ dm3 ϭ 103 cm3 ϭ 106 mm3) Mass kilogram (kg) pound (lb) Density kg/m3 1.0 ton (short) ϭ 2,000 lb ϭ 907.2 kg ton lb/in3 1.0 lb/in3 ϭ 27.68 ϫ 103 kg/m3 lb/ft 1.0 lb/ft3 ϭ 16.0184 kg/m3 ft/min 1.0 ft/min ϭ 0.3048 m/min ϭ 5.08 ϫ 10Ϫ3 m/s BCOVER.indd 1.0 lb ϭ 0.4536 kg Velocity m/min m/s in/min 1.0 in/min ϭ 25.4 mm/min ϭ 0.42333 mm/s Acceleration m/s2 ft/sec2 1.0 ft/sec ϭ 0.3048 m/s2 7/18/12 2:38 PM Force Newton (N) pound (lb) 1.0 lb ϭ 4.4482 N Torque N-m ft-lb, in-lb 1.0 ft-lb ϭ 12.0 in-lb ϭ 1.356 N-m 1.0 in-lb ϭ 0.113 N-m Pressure Pascal (Pa) 1.0 lb/in2 ϭ 6895 N/m2 ϭ 6895 Pa lb/in Stress Pascal (Pa) lb/in 1.0 lb/in2 ϭ 6.895 ϫ 10Ϫ3 N/mm2 ϭ 6.895 ϫ 10Ϫ3 MPa Energy, work Joule (J) ft-lb, in-lb 1.0 ft-lb ϭ 1.356 N-m ϭ 1.356 J 1.0 in-lb ϭ 0.113 N-m ϭ 0.113 J Heat energy Joule (J) British thermal unit (Btu) 1.0 Btu ϭ 1055 J Power Watt (W) Horsepower (hp) 1.0 hp ϭ 33,000 ft-lb/min ϭ 745.7 J/s ϭ 745.7 W 1.0 ft-lb/min ϭ 2.2597 ϫ 10Ϫ2 J/s ϭ 2.2597 ϫ 10Ϫ2 W Btu/lb-°F 1.0 Btu/lb-°F ϭ 1.0 Calorie/g-°C ϭ 4,187 J/kg-°C Thermal conductivity J/s-mm-°C Btu/hr-in -°F 1.0 Btu/hr-in -°F ϭ 2.077 ϫ 10Ϫ2 J/s-mm-°C Thermal expansion (in/in)/°F 1.0 (in/in)/°F ϭ 1.8 (mm/mm)/°C Specific heat Viscosity J/kg-°C (mm/mm)/°C Pa-s lb-sec/in 1.0 lb-sec/in2 ϭ 6895 Pa-s ϭ 6895 N-s/m2 CONVERSION BETWEEN USCS AND SI: To convert from USCS to SI: To convert the value of a variable from USCS units to equivalent SI units, multiply the value to be converted by the right-hand side of the corresponding equivalency statement in the Table of Equivalencies Example: Convert a length L ϭ 3.25 inches to its equivalent value in millimeters Solution: The corresponding equivalency statement is: 1.0 in ϭ 25.4 mm L ϭ 3.25 in ϫ (25.4 mm/in) ϭ 82.55 mm To convert from SI to USCS: To convert the value of a variable from SI units to equivalent USCS units, divide the value to be converted by the right-hand side of the corresponding equivalency statement in the Table of Equivalencies Example: Convert an area A ϭ 1000 mm2 to its equivalent in square inches Solution: The corresponding equivalency statement is: 1.0 in2 ϭ 645.16 mm2 A ϭ 1000 mm2 /(645.16 mm2/in2) ϭ 1.55 in2 BCOVER.indd 7/18/12 2:38 PM ... FEATURES OF THIS BOOK AND ITS WEBSITE FOR STUDENTS: Fundamentals of Modern Manufacturing: Materials, Processes, and Systems contains 40 chapters Chapter provides an introduction and overview of manufacturing. .. Weiss, R Nagel, and N Odrey) Automation, Production Systems, and Computer Integrated Manufacturing, Prentice Hall, 1987 Fundamentals of Modern Manufacturing: Materials, Processes, and Systems, originally... the Author Fundamentals of Modern Manufacturing: Materials, Processes, and Systems, Third Edition, John Wiley & Sons, Inc., 2007 Automation, Production Systems, and Computer Integrated Manufacturing,