Manufacturing processes and materials

Tai ngay!!! Ban co the xoa dong chu nay!!! Manufacturing Processes & Materials Fifth Edition Ahmad K Elshennawy Gamal S Weheba Dearborn, Michigan Copyright © 2015 by Society of Manufacturing Engineers 987654321 All rights reserved, including those of translation This book, or parts thereof, may not be reproduced by any means, including photocopying, recording or microfilming, or by any information storage and retrieval system, without permission in writing of the copyright owners No liability is assumed by the publisher with respect to use of information contained herein While every precaution has been taken in the preparation of this book, the publisher assumes no responsibility for errors or omissions Publication of any data in this book does not constitute a recommendation or endorsement of any patent, proprietary right, or product that may be involved Library of Congress Catalog Card Number: 2013954872 International Standard Book Number (10 digit): 0-87263-871-5, (13 digit) 9780872638716 Additional copies may be obtained by contacting: SME Customer Service One SME Drive, P.O Box 930 Dearborn, Michigan 48121 1-800-733-4763 www.sme.org Video content online Visit www.sme.org/MPM SME staff who participated in producing this book: Rosemary Csizmadia, Senior Production Editor Janet Zasadny and Karen Lewis, Administrative Assistants Christine Verdone, Cover Design Jerome Cook, Video Producer Cover photos courtesy of Lance Rosol Printed in the United States of America CONTENTS About the Authors ix Purpose of This Text xi Text Background; Scope of Coverage; Use and Application; Organization of the Text Acknowledgments xv Manufacturing Foundations Manufacturing; Hand Tools to Machine Tools; Types of Products; Organization for Manufacturing; Questions; References The Competitive Challenge in Manufacturing 13 Importance of Manufacturing as an Economic Activity; State of the Industry; Labor Productivity; International Competitiveness; Manufacturing Innovations; Questions; References Material Properties and Testing 23 Metal Structures; Metallurgy of Iron and Steel; Testing of Engineering Materials; Questions; Problems; References Iron and Steel 57 Iron, Steel, and Power; Iron Making; The Blast Furnace and Its Chemistry; Steelmaking; Finishing and Ingot Teeming; Special Techniques in Steel Refining; Aluminum; Copper; Miscellaneous Metals; Steel; Effects of Alloying Elements in Ferrous Alloys; Carbon Steels; Alloy Steels; Questions; References Nonferrous Metals and Alloys 79 Effects of Alloying on Properties; Aluminum; Magnesium; Copper; Zinc; Titanium; Nickel and Its Alloys; The White Metals; Refractory Metals; Precious Metals; Questions; References Manufacturing Processes & Materials, Fifth Edition v vii Manufacturing Processes & Materials, Fifth Edition Contents 16 Measurement and Gaging 357 Purpose and Definitions; Standards; Instruments; Coordinate Measuring Machines; Automatic Gaging Systems; Measuring with Light Rays; Surface Quality; Manufacturing Specifications; Questions; Problems; References 17 How Metals are Machined 403 Importance of Metal Machining; Basic Processes; Mechanics of Metal Cutting; Metal Machining Conditions; Metal-cutting Tools; Cutting Fluids; Questions; Problems; References 18 Turning, Boring, and Facing 431 Turning Operations; The Lathe; Accessories and Attachments; Lathe Operations; Production Turning Machines; Machining Time and Material Removal Rate; Questions; Problems; References 19 Process Planning and Cost Evaluation 457 Introduction; Preproduction Process Planning; Process Plan Development; Economics of Process Planning; Machine Tool Selection; How Costs are Estimated and Compared; Questions; Problems; References 20 Drilling and Allied Operations 481 Operations Defined; Drills, Boring Tools, and Reamers; Drilling Machines; Drilling Machine Accessories and Attachments; Boring Machines; Drilling and Boring Operations; Process Planning; Questions; Problems; References 21 Milling 509 Evolution of Flat Surface Generating Processes; Milling Process; Milling Cutters and Drivers; Milling Machines; Process Planning; Questions; Problems; References 22 Broaching and Sawing 531 Broaching; Sawing; Questions; Problems; References 23 Abrasives, Grinding Wheels, and Grinding Operations 551 Abrasives; Grinding Wheels; Other Abrasive Products; Grinding Operations; Economics; Questions; Problems; References 24 Grinding Machines and Methods 573 Precision Grinders; Nonprecision Grinders; Grinding Compared with Other Operations; Questions; Problems; References 25 Ultra-finishing Operations 595 Lapping; Honing; Microfinishing; Burnishing and Bearingizing; Nonprecision Deburring and Finishing Processes; Process Planning; Questions; References 26 Other Surface Enhancement Processes 613 Cleaning; Surface Coatings; Green Manufacturing; Questions; Problems; References 27 Nontraditional Manufacturing Processes 629 Chemical Machining Processes; Electrochemical/Electrolytic Machining Processes; Thermal Machining Processes; Waterjet Machining (WJM); Questions; Problems; References viii Manufacturing Processes & Materials, Fifth Edition Contents 28 Thread and Gear Manufacturing 651 Screw Threads and Screws; Gears; Questions; Problems; References 29 Manufacturing Systems 689 Introduction; Manufacturing Systems; Manufacturing Technologies; Lean Manufacturing; Rapid Prototyping and Manufacturing; Questions; References 30 Flexible Program Automation 707 Classes of Automation; Manned Cell Partial Automation; Unmanned Cell Automation; Computer Integration; Economic Justification of an Automated System; Questions; Problem; References Index 733 About the Authors Co-authors Ahmad Elshennawy and Gamal Weheba share their wealth of practical experience and technical knowledge of manufacturing processes and materials in this comprehensive text Ahmad K Elshennawy, Ph.D is Associate Chair and Professor in the Department of Industrial Engineering and Management Systems at the University of Central Florida (UCF) Prior to joining UCF in 1986, he served as a guest researcher with the Precision Engineering Division of the National Institute of Standards and Technology (NIST) With over 30 years of international experience as a researcher, academician, and a consultant, Dr Elshennawy’s areas of expertise include manufacturing processes and systems, quality and reliability engineering, lean manufacturing strategies, and business and process performance improvement and management He received B.S and M.S degrees in Production Manufacturing Processes & Materials, Fifth Edition Engineering from Alexandria University (Egypt) and M Eng and Ph.D degrees in Industrial Engineering from Penn State University Dr Elshennawy is a fellow of the American Society for Quality (ASQ), and a senior member of the Institute of Industrial Engineers (IIE) and SME He is an ASQ Certified Quality Engineer, a Certified Reliability Engineer, and a Lean Six Sigma Master Black Belt G a m a l S Weheba, Ph.D is a Professor in the Department of Industrial and Manufacturing Engineering at Wichita State University He received a B.S in Production Engineering from Menoufia University (Egypt) and a Ph.D in Industrial Engineering and Management Systems from the University of Central Florida Since 1981 he has taught courses on industrial engineering and manufacturing-related subjects at Menoufia University (Egypt), the University of Central Florida, and Wichita State University Dr Weheba has performed research in the areas of quality ix x Manufacturing Processes & Materials, Fifth Edition management systems, statistical process control, reliability engineering, product design optimization, and quality improvement He applies his expertise in these areas and in additive manufacturing and rapid tooling to solve problems pertaining to quality and productivity of manufacturing systems, manufacturing of composites, and rapid prototyping He is a fellow of ASQ, an ASQ Certified Quality Engineer, and a senior member of SME About the Authors Purpose of This Text Manufacturing involves a complex system of people, machines, materials, and money organized to produce a product There are a number of components to every manufacturing organization, each of which requires people with different education, training, and experience with different levels of skills The technical departments within such an organization, for example product design, production engineering, manufacturing engineering, industrial engineering, tool engineering, quality engineering, and the production function itself, all require technical personnel with an appropriate degree of knowledge of the manufacturing process This text is dedicated to providing the reader with an understanding of the basic processes and equipment used in manufacturing so that he or she might work more productively within those technical areas of manufacturing Since the scope of manufacturing is extremely broad, a single textbook cannot expect to address the whole spectrum of machines and processes that might be applicable to such a diverse field Instead, different textbooks tend to limit their scope to those areas of manufacturing wherein the authors’ interest and proficiency are greatest In this text, the scope of coverage is more or less limited to the basic machines and processes used in the forming, machining, and fabricating of products and parts made of metallic and nonmetallic materials Manufacturing Processes & Materials, Fifth Edition TEXT BACKGROUND Much of the coverage of the basic manufacturing processes stems from the earlier work of Lawrence E Doyle who was Professor of Mechanical Engineering at the University of Illinois-Champaign/Urbana Professor Doyle, with the assistance of contributing authors C A Keyser, J L Leach, J L Morris, G F Schrader, and M B Singer, prepared three successive editions of Manufacturing Processes and Materials for Engineers (Prentice-Hall, Inc., 1961, 1969, and 1985) In addition to the background provided by Professor Doyle and his colleagues, recognition must be given to Dr Vimal H Desai, who was Associate Professor of Engineering at the University of Central Florida, for his consultative input Dr George F Schrader, Emeritus Professor of Engineering at the University of Central Florida, and Dr Ahmed K Elshennawy prepared the Fourth Edition They focused their contributions on advanced equipment and contemporary manufacturing methods and materials This book is a revision of the Fourth Edition, which recognizes changes in the manufacturing curricula and industry that have taken place since 2000 SCOPE OF COVERAGE The basic processes of manufacturing have not changed significantly since the Industrial xi xii Manufacturing Processes & Materials, Fifth Edition Revolution For example, metals are still cast in sand molds, formed metal parts are still stamped on punch presses, cylindrical parts are turned on lathe-like turning machines, and surfaces are ground with abrasive wheels and stones However, the supporting technologies, such as machines, cutting tools, controls, and measuring instruments for these processes have made tremendous advances This has permitted manufacturing companies to improve the efficiency and effectiveness of operations and the quality and reliability of the products produced This edition focuses on the basic machines and tools applicable to the job shop, toolroom, or small-volume manufacturing facility At the same time, it will expose the reader to some of the more advanced equipment used in larger volume production environments USE AND APPLICATION Manufacturing Processes & Materials has been designed for use at several levels of the informal and formal educational process It can be used as an introductory text for in-plant training of manufacturing personnel Or, at the other extreme, it can be used as an advanced text at the college or university level where it will provide a comprehensive manufacturing educational background for technical students in a variety of disciplines Because of the breadth of coverage, it is recommended for a two-semester or two-quarter sequence in conjunction with a manufacturing laboratory In addition, the text will be useful as a reference for technical students and manufacturing personnel ORGANIZATION OF THE TEXT Chapter introduces the reader to traditional manufacturing It is a must read for students who have not been exposed to a manufacturing environment or who may not have any knowledge or appreciation for the complexities of that environment Chapter describes many of the challenges that manufacturing establishments must face if they expect to remain competitive in a global environment The next five chapters are concerned with engineering materials, their physical proper- Purpose of This Text ties, testing, treatment, and suitability for use in manufacturing These chapters should be required reading for students with little or no preparation in these subject areas Chapter is dedicated to a discussion of the commonly used composite materials and the various processes used to manufacture composite products It introduces the reader to basic knowledge of materials and processes utilized to manufacture composite structures The chapter includes a description of methods used to determine the fundamental properties of composites before and after manufacturing The chapters concerned with the machines, tools, and processes of manufacturing are arranged in accordance with the traditional hierarchy for conversion of raw materials into a finished product via a variety of casting, forming, joining, and machining processes Chapter 16 follows with a rather extensive treatment of measuring and gaging instruments used for assessing conformance to specifications Chapter 19 introduces the reader to the planning process and to a number of economic methods for comparing alternatives In addition, many of the other chapters include materials on process planning and economic analysis with reference to a particular set of processes or machines The importance of planning in any manufacturing environment must be emphasized if the results are to be cost-effective, on-time, and on-quality Production planners and manufacturing engineers will agree that the manufacturing planning process is filled with choices With the current emphasis on continuous improvement (justin-time and lean/agile manufacturing) making the right choice the first time is critical to the competitive status of companies Thus, it is important that personnel involved in planning are knowledgeable about the alternative processes available, the capabilities of those processes, and the economic advantage of one process over another For example, as explained in Chapter 21 on milling, there are probably 40 or 50 different operations that can be performed on the versatile milling machine and its newer likeness, the machining center These operations range from drilling a hole to cutting a keyway Each of these operations can be done on any one of a dozen or Index Terms Links stresses (material) 38–40 (Table 3-1, 3-2) stress-strain relationship 229 (Fig 12-2) stretch bending/forming 263 (Fig 13-8) stretching and drawing 265–277 (Fig 13-10 to 13-18) stub arbor 512 stub tooth 665 stud 273–274 (Fig 13-17) 354 (Fig 15-9) stud welding 321 submerged-arc welding 307 (Fig 14-6) 310–311 (Fig 14-9) 338 (Table 14-2) submerged-electrode furnace 108 sulfur (alloying element) 190 sull 236 superabrasives 552–554 (Table 23-1, Fig 23-2) superfinishing 600–604 (Fig 25-7 to 25-10) Superfund 600 625 superhard crystalline cutting tools 416–417 surface, broaching machine characteristics 537 539 (Fig 22-10) 389 (Fig 16-33) coatings 615–624 (Fig 26-2 to 26-4) finish 390–391 (Fig 16-34, 16-35) 442–443 645 form generation 403–404 (Fig 17-1, 7-2) grinders 581–583 (Fig 24-1024-11, Table 24-2) grinding 558 hardening (steel) 565 (Fig 23-13) 99–103 plate 365 quality 388–392 (Fig 16-33 to 16-35) tension 221 surfacing 350–351 swaging 278–279 (Fig 13-20) sweeps 171 (Fig 9-14) swing-frame grinders 588 Swiss automatic lathe 453 (Fig 18-19) Systeme International d’Unites 357 This page has been reformatted by Knovel to provide easier navigation 367 (Fig 16-14) Index Terms Links T tack 144 fabrics 143 testing 154–156 (Fig 8-14) thermoplastics 141 (Table 8-1) thermoset prepregs thermosets 144 140–141 (Table 8-1) tow 143 weave 143–145 (Fig 8-4) wet layup 147 (Fig 8-6) yarn 143 tailstock (lathe) 433–435 (Fig 18-4, 18-5) takt time 700 tantalum 86 tap hole 179 taper 433 (Fig 18-3) attachment (lathe) shank socket 440 (Fig 18-10) 442 492 thread 651–652 (Fig 28-1) turning 403–404 (Fig 17-1) tapping machines 431–433 (Fig 18-1, 18-3) 661 (Fig 28-14, 28-15) taps (threading) 659–660 (Fig 28-13) Taylor, Frederick W teeming 64 testing (materials) 23–55 apparent stress-strain 40 bend tests 47 brittleness 40 composites 154–157 (Fig 8-14, 8-15) corrosion test 51–52 ductility 40 elastic action 38–39 engineering stress-strain relationship fatigue test 40 48 (Fig 3-25, 3-26) fracture toughness tests 50 This page has been reformatted by Knovel to provide easier navigation Index Terms Links testing (materials) (Cont.) gamma ray test 50 hardness test 44–45 high-temperature tests 47–48 (Fig 3-24) inelastic action 39 Magnaflux test 50 magnetic particle 50 mechanical 37 modulus of elasticity 38 necking down 40 neutron radiography 50 nondestructive test 50 notched-bar impact 46–47 springback 38 stiffness 38 strains 156–157 (Fig 8-15) 38–40 (Table 3-1, 3-2) stress-rupture test 48 stresses 38–40 (Table 3-1, 3-2) tension test 38 (Fig 3-17) toughness 44 ultrasonic testing 51 unit changes in length 38 unit loads 38 x-ray test 50 yield point 39 yield strength 40 Young’s modulus 38 thermal, cutting 343–348 (Fig 15-1 to 15-6) effect (grinding) 566–567 (Fig 23-14) energy deburring 609 machining 344 (Fig 15-2) thermit welding 638–647 (Fig 27-9 to 27-13) 323–325 (Fig 14-22) thermochemical machining thermomagnetic forming thermoplastic materials 631 328–329 113–119 (Table 7-1) This page has been reformatted by Knovel to provide easier navigation 145–146 Index Terms Links thermosets 114–119 (Fig 7-4) thread manufacturing 144 651–664 (Fig 28-1 to 28-16) American National Acme 652 (Fig 28-2) American National Standards Institute 653 chasing 656 classes 654 cutting 656–661 (Fig 28-7 to 28-14) design for tapping diameter 660–661 652 (Fig 28-1) die 658–659 (Fig 28-10, 28-11) die machine 663 (Fig 28-16) errors 655–656 external/internal 651–652 (Fig 28-1) forms 652–653 (Fig 28-2, 28-3) gages 368 370–371 (Fig 16-15) 656 (Fig 28-6) lathe 656–661 (Fig 28-7 to 28-14) lead 651–652 (Fig 28-1) left-hand/right-hand machines 651 659 (Fig 28-12) measurement 654–656 (Fig 28-4 to 28-6) metric form 652–653 (Fig 28-3) micrometer 368–371 (Fig 16-15) micrometer caliper milling 655 661–662 pitch 651–652 (Fig 28-1) pitch gage 656 relief groove 658 (Fig 28-9) rolling 662–664 (Fig 28-16) sharp V thread 652 standards 652–654 straight/taper 651–652 (Fig 28-1) tapping machines 661 (Fig 28-14, 28-15) taps 659–660 (Fig 28-13) unified national 653 Unified Screw Form 652 (Fig 28-2) This page has been reformatted by Knovel to provide easier navigation 664 Index Terms Links thread gage 368 370–371 (Fig 16-15) 656 (Fig 28-6) threaded fasteners 354 (Fig 15-9) threading 432–433 (Fig 18-1, Fig 18-3) Tig welding 658–659 (Fig 28-10, 28-12) 309 time 540–541 broaching 540–541 drilling 501 handling 447 milling 470–473 (Fig 19-7, Table 19-1) 526–527 setup 470 takt 700 turning 447 tin 453–454 (Fig 18-20) 68 tin dipping/plating 619 TIR 437 titanium 68–69 alloys 85 carbide 135 carbide/molybdenum/nickel tools nitride 414–415 135 tolerance 398–400 (Fig 16-41, 16-42) 100% interchangeability 442–443 395–398 allowance 395 397 (Fig 16-39) ANSI B4.2-1978 395 397 (Fig 16-39) basic size 395 bilateral 393 casting design 197 form 399 (Fig 16-41) gage 373–374 (Fig 16-17, 6-18) dimensions 393 manufacturing 392–394 (Fig 16-36, 16-37) maximum material condition 398 positional 398–400 (Fig 16-42) standard hole/shaft practice 395–396 (Fig 16-38) standard size 395 This page has been reformatted by Knovel to provide easier navigation Index Terms Links tolerance (Cont.) unilateral 393 tool and cutter grinders angles 290–296 (Fig 13-32, 13-33) 413–424 (Table 17-1, Fig 17-11 to 17-19) 446 (Fig 18-15) 634–635 (Fig 27-4) 586–590 (Fig 24-18, 24-21) 417–420 (Fig 17-12, 17-13, Table 17-2) approach 470 body 417–418 (Fig 17-12) carbides 414–415 carbon tool steel 413–414 cast nonferrous alloys ceramics/cermets 414 419 (Table 17-2) 419 (Table 17-2) 415–416 chip breakers 420–422 (Fig 17-15) comparison 417 (Fig 17-11) coolant 424–426 cost 417 (Fig 17-11) cutting fluids 424–426 force 408 (Fig 17-7, 17-8) form 424–425 (Fig 17-20) high-speed steel holder 414 419 (Table 17-2) 424 (Fig 17-18, 17-19) 446–447 (Fig.18-15) 492 (Fig 20-17) industrial diamond insert shapes 416–417 422–424 (Fig 17-16, 17-17) ISO 513 415 life 412 material 413–417 (Table 17-1) nose radius 420 (Fig 17-14) orbited 643 overtravel 470 oxides 415–416 penetration 406 (Fig 17-3) point 417 polycrystalline cubic boron nitride post grinder shank 416–417 573 417–418 (Fig 17-12) This page has been reformatted by Knovel to provide easier navigation 423–424 (Fig 17-18) Index Terms Links tool (Cont.) shapes 417–424 (Fig 17-16, 17-17) steels 73–74 (Table 4-4) superhard crystalline wear 416–417 412 toolholder 424 (Fig 17-18, 17-19) 446–447 (Fig 18-15) 492 (Fig 20-17) toolroom lathe 436 tooth comparator 682 tooth rounding/chamfering 677 total indicator reading 437 touch-trigger probe 383 toughening steel 96 toughness (material) 44 tow 143 Toxic Substance Control Act 625 Toyota Motor Company 693 Toyota Production System 693 697 701 tracer lathe 437 transfer lines 709–711 (Fig 30-4, 30-5) computer-aided process planning 728–729 (Fig 30-18) machining center 723–724 (Fig 30-15) turning center 723 unmanned cells 721–727 (Fig 30-13 to 30-16) work positioning 718 transfer molding 126 (Fig 7-7) trepanning 486 trimming 257–258 (Fig 13-1) trimming press 286 tri-way mill 515 true strain/true stress 41–43 (Table 3-2, Fig 3-19, 3-20) truing (grinding wheel) 561–562 (Fig 23-10) tube/tubing 237–238 (Fig 12-11) -bending mandrels forming 263 (Fig 13-8) 272 (Fig 13-16) This page has been reformatted by Knovel to provide easier navigation 729–730 (Fig 30-19) Index Terms Links tube/tubing (Cont.) hone 598 (Fig 25-3) swaging 278 (Fig 13-20) Tukon tester 45 tumbling 606 (Fig 25-14) 610 tungsten 69 86 carbide 135 carbide/cobalt tools 414–415 -titanium carbide/cobalt tools 414–415 turning 403–404 (Fig 17-1) automatic machines boring 448–453 (Table 18-2, Fig 18-17 to 18-20) 431–456 (Fig 18-3) cells 449 center drill an d countersink chuck work 432 (Fig 18-2) 431 contours 433 (Fig 18-3) 432 (Fig 18-1) cut 447 drill holder 446–447 (Fig 18-15) drilling 433 (Fig 18-3) facing 431–456 (Fig 18-1, 18-3) forming 432–433 (Fig 18-1, 18-3) heads 447 knurling 432 (Fig 18-1) lathe 432–453 (Table 18-2, Fig 18-3 to 18-20) material removal rate necking 453–454 (Fig 18-20) 432 (Fig 18-1) operations 442–443 plain 447–448 431 (Fig 18-1) process integration production machines straight 431–456 449 443–453 (Fig 18-13 to 18-20, Table 18-2) 431 (Fig 18-1) 433 (Fig 18-3) 454 (Fig 18-20) taper threading 431–433 (Fig 18-1, 18-3) 432–433 (Fig 18-1, Fig 18-3) time 447 tools 446 (Fig 18-15) This page has been reformatted by Knovel to provide easier navigation 453–454 (Fig 18-20) Index Terms Links turret drill press 490–492 (Fig 20-14) turret lathe 443–448 (Fig 18-13 to 18-15) 451 470–474 (Fig 19-7, Table 19-1, 19-2) twinning 26 twist drill 482 (Fig 20-1) 484 (Fig 20-4, 20-5) U ultimate strength 26 ultra-finishing 595–611 (Fig 25-1 to 25-16) ultrasonic, forming 277 impact grinding 603–604 (Fig 25-11) machining 603–604 (Fig 25-11) nano-welding 339 testing 51 transducer 603–604 (Fig 25-11) welding 328–339 undercuts (welding) 332 underdrive press 286 Unified Screw Thread Form 652 (Fig 28-2) unit cells 23–24 (Fig 3-2) unit loads 38 universal, chuck 437–438 (Fig 18-6, Table 18-1) cylindrical center-type grinder dividing head (milling) 576 (Fig 24-5, Table 24-1) 520 (Fig 21-16) machining center 723 thread miller 662 tool and cutter grinder unmanned cells 520 (Fig 21-15) 586–588 (Fig 24-18) 695 721–727 (Fig 30-13 to 30-16) 729–730 (Fig 30-19) up milling upset forging upset-butt welding 522 245–246 (Fig 12-18, 12-19) 322 (Fig 14-20) This page has been reformatted by Knovel to provide easier navigation Index Terms Links V vacuum, arc remelting 65 bag molding 129–130 (Fig 7-10) casting 186 degassing 185 (Fig 9-31) deposition 622–623 furnace 183 200 105 injection molding 129–130 (Fig 7-10) melting 183–185 (Fig 9-30) metallizing 622–623 value added 14 vanadium (alloying element) 190 vapor degreasing 614 (Fig 26-1) vapor deposition 622–623 VAR 65 variable inductance transducer 375–376 (Fig 16-21) variable transformer 375–376 (Fig 16-21) variant computer-aided process planning 728–729 (Fig 30-18) varnishes 616 vents (mold) 164 vernier caliper 361–363 (Fig 16-3, 16-4) vernier height gage 362 (Fig 16-5) vertical, band saw machine 546 boring machines 448 broaching machine drill press 534–537 (Fig 22-6) 488–489 (Fig 20-11, 20-12) honing machine 598–599 (Fig 25-4) internal grinder 580 lapping machine 596 (Fig 25-1) machining center 723–724 (Fig 30-15) turret lathe welding 448 (Fig 18-16) 311–312 (Fig 14-10) This page has been reformatted by Knovel to provide easier navigation 539 (Fig 22-10) Index Terms Links vibration 412–413 vibratory finishing 606 (Fig 25-14) Vickers tester 45–46 (Fig 3-22) vise (milling) 519 vitreous coatings 624 voids (welding) 332 volume diffusion 221–222 (Fig 11-5) vulcanization 120 W walking beam furnace 106 warm, extrusion 251 forming 230 heading 277 working 230 warp fabrics/yarns 251 143 washers 355 (Fig 15-9) Water, as cutting fluid 425 -base paints 616 -borne paints 616 solutions (cleaning) 613 Quality Act 625 waterjet cutting 647 waterjet machining 607 Watt, James waviness (surface) 389 waxes (cutting) 426 wear allowance (gage) 373 weathering steels weave 72 143–145 (Fig 8-4) wedge rolling 247 weft fabrics 143 welding arc blow 301–342 (Fig 14-1) 306 This page has been reformatted by Knovel to provide easier navigation 647 Index Terms Links welding (Cont.) arc booster 308 arc process comparison 337–338 arc-spot 310 arc-stud 312 (Fig 14-11) atomic hydrogen-arc 309–310 automatic arc 307–308 automation 338–339 braze 351 bronze 351 bulk-process 351 capacitor-discharge 312 (Fig 14-11) carbon-arc 301 closed-gap 327 corrosion 333 cost 334–338 (Fig 14-29, 14-31, Table 14-2) current 305–309 (Fig 14-7) defect 332–334 (Fig 14-28) design 333–334 (Fig 14-28) diffusion bonding 328 electric-arc 301–306 (Fig 14-2 to 14-5) electrodes electrogas/electroslag electromagnetic forming electron beam energy-ray 301 303 (Fig 14-2) 306–307 311 311–312 (Fig 14-10) 328–329 312–313 (Fig 14-12) 312–315 (Fig 14-12, 14-13) explosion 328 faying surfaces 316 FCAW 311 flash-butt forge friction fusion gas gas-metal arc 322–323 (Fig 14-21) 327 327–328 301 325–327 (Table 14-1, Fig 14-23) 309 (Fig 14-8) This page has been reformatted by Knovel to provide easier navigation Index Terms Links welding (Cont.) gas-shielded arc 308–310 (Fig 14-8) gas-tungsten arc 309 (Fig 14-8) gun 338 (Table 14-2) 320 heat balance 315–316 high-frequency 319–320 (Fig 14-17) 317 inertia 327–328 inspection 334 joints 301 laser 329–330 (Fig 14-25) 314–315 (Fig 14-13) magnet-arc 323 magnetic flux 311 manual-arc 307 336 (Fig 14-29) metal-arc 301 303–304 (Fig 14-2 to 14-4) 338 (Table 14-2) 311 metallurgy 330–332 (Fig 14-27) micro wire 310 Mig 310 nano- 339 narrow gap 311–312 oxyacetylene gas 326–327 (Table 14-1, Fig 14-23, 14-24) parameters 303–304 penetration 303 percussion 323 performance 304–305 (Fig 14-5) PIGME 310 polarity 304–305 plasma arc 301 positioners 307 post-heating 333 power sources 309 (Fig 14-7) programmed, inert-gas, multi-electrode welding 310 projection 320–321 (Fig 14-18) pulsed-arc 309 quality 332–334 (Fig 14-28) This page has been reformatted by Knovel to provide easier navigation 309–310 (Fig 14-8) Index Terms Links welding (Cont.) resistance 315–323 (Fig 14-14 to 14-21) roll bonding 328 seam 321–322 (Fig 14-19) shrinkage 332–333 solid-state 327–329 spot 318–320 (Fig 14-15, 14-16) stud 321 submerged-arc 307 (Fig 14-6) 310–311 (Fig 14-9) 338 (Table 14-2) symbols 329–330 (Fig 14-26) technique performance factor temperature 304 331 (Fig 14-27) thermit 323–325 (Fig 14-22) thermomagnetic forming 328–329 Tig 309 tungsten-arc 301 ultrasonic 328 undercuts 332 upset-butt 322 (Fig 14-20) vertical 311–312 (Fig 14-10) voids 332 vs casting cost 335 vs riveting cost 336–337 weldment design wet layup of fabric wheel lathe white cast iron white metals 339 334 (Fig 14-28) 147 (Fig 8-6) 436 189 (Fig 9-34) 86 White, Mansel Whitney, Eli Whitworth, Joseph Wilkinson, John wing bending 264 WJM 647 wood patterns 171 This page has been reformatted by Knovel to provide easier navigation 337 (Fig 14-31) Index Terms Links work, handling time (lathe) 447 -harden (metals) 26 -hardening coefficient 42 in process 701 positioning (automation) 718 worker time 470 workflow (lean) 700–701 workholding devices World Trade Organization worm gear 439 493–494 520 534 17 667 (Fig 28-22) woven fabric 143 wrought metals 227 X x-ray test 50 Y yarn 143 yield point 39 228 yield strength 26 40 Young’s modulus 38 Z zero inventory zerol-bevel gear zinc zinc alloys zirconia zirconium zirconium oxide 693 668 (Fig 28-23) 68 84–85 135 86 135 This page has been reformatted by Knovel to provide easier navigation