Introduction to manufacturing processes

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FFIRS 08/16/2011 16:20:31 Page FFIRS 08/16/2011 16:20:31 Page INTRODUCTION TO MANUFACTURING PROCESSES FFIRS 08/16/2011 16:20:31 Page FFIRS 08/16/2011 16:20:31 Page INTRODUCTION TO MANUFACTURING PROCESSES Mikell P Groover Professor Emeritus of Industrial and Systems Engineering Lehigh University JOHN WILEY & SONS, INC FFIRS 08/16/2011 16:20:31 Page VP & EXECUTIVE PUBLISHER EXECUTIVE EDITOR EDITORIAL ASSISTANT MARKETING MANAGER PRODUCTION MANAGER SENIOR PRODUCTION EDITOR DESIGNER Don Fowley Linda Ratts Christopher Teja Clay Stone Janis Soo Joyce Poh Seng Ping Ngieng Cover image: Photo courtesy of Sandvik Coromant This book was set in 9.5/11.5 Times Roman by Thomson Digital and printed and bound by RR Donnelley The cover was printed by RR Donnelley 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 # 2012 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 http://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 Outside of the United States, please contact your local representative Library of Congress Cataloging-in-Publication Data Groover, Mikell P., 1939Introduction to manufacturing processes / Mikell P Groover p cm Includes index ISBN 978-0-470-63228-4 (pbk.) Manufacturing processes Production engineering I Title TS183.G785 2012 670—dc23 2011025938 Printed in the United States of America 10 FFIRS02 07/01/2011 18:24:42 Page PREFACE Introduction to Manufacturing Processes is designed for a first course in manufacturing at the junior level in mechanical, industrial, and manufacturing engineering curricula It may also be appropriate for technology programs related to these engineering disciplines The book is based largely on my other manufacturing book, Fundamentals of Modern Manufacturing: Materials, Processes, and Systems That book is approximately 1000 pages long, and it competes with other manufacturing textbooks that are also very long Complaints are sometimes leveled that these books include more content than can possibly be covered in a one-semester course The counterargument to that complaint is that these very comprehensive volumes will serve as valuable references for students in their future professions, assuming those professions are related to design and/or manufacturing With this new book, we are attempting to provide an offering that is significantly shorter than the other texts (about 700 pages versus a thousand or more pages) To decide on the coverage of this text, John Wiley & Sons conducted a survey of faculty who have adopted the Fundamentals book or its competitors to determine which topics they considered most important in their respective courses Based on the feedback from that survey, we developed the topical content of the current book, which focuses on manufacturing processes Coverage of engineering materials has been reduced from eight chapters to two, and coverage of production systems has been reduced from five chapters to three The two chapters dealing with electronics manufacturing have been eliminated because our survey showed that many mechanical engineering instructors not feel the need to include this area in their courses Finally, there are several instances in which I combined chapters All of these changes have resulted in a new book that contains a total of 30 chapters, compared with 42 chapters for the fourth edition of the Fundamentals book The chapters on manufacturing processes are taken almost verbatim from Fundamentals In some cases, I have shortened the coverage by omitting certain processes or details about processes that seemed appropriate for the more comprehensive text but not for this introductory version The emphasis on manufacturing science and mathematical modeling of processes remains an important attribute of the new book Readers will notice that the Historical Notes and end-of-chapter Multiple-Choice Questions have been eliminated from the new book End-of-chapter Review Questions and Problems have been retained, but the number of problems has been reduced All of these changes have been made to reduce page count, which results in a textbook that includes most of the topics that are covered by most instructors who teach courses in manufacturing For instructors who require a more comprehensive treatment of the subject than is contained in this new book, we hope they will continue to adopt the Fundamentals book SUPPORT MATERIALS FOR INSTRUCTORS For instructors who adopt this book for their courses, the following support materials are available: å A Solutions Manual (in digital format) covering all problems and review questions å A complete set of Powerpoint slides for all chapters v FFIRS02 07/01/2011 vi 18:24:42 Page Preface These support materials and others 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 FFIRS03 07/01/2011 18:27:56 Page ACKNOWLEDGMENTS I would like to express my appreciation to the following people who served as participants in our survey that resulted in the decisions on content for this book: Yuan-Shin Lee, North Carolina State University; Ko Moe Hun, University of Hawaii; Ronald Huston, University of Cincinnati; Ioan Marinescu, University of Toledo; Val Marinov, North Dakota State University; Victor Okhuysen, California Polytechnic University, Pomona; John M Usher, Mississippi State University; Daniel Waldorf, California Polytechnic State University; Allen Yi, Ohio State University; Jack Zhou, Drexel University; and Brian Thompson, Michigan State University In addition, it seems appropriate to acknowledge my colleagues at Wiley in Hoboken, New Jersey: Executive Editor Linda Ratts, Editorial Assistants Renata Marcionne and Christopher Teja, and Production Editor Micheline Frederick Last but certainly not least, I appreciate the thorough efforts of editor Joyce Poh at Wiley in Singapore vii FFIRS04 07/01/2011 18:31:18 Page ABOUT THE AUTHOR Mikell P Groover is Professor Emeritus of Industrial and Systems Engineering at Lehigh University He received his B.A in Arts and Science (1961), B.S in Mechanical Engineering (1962), M.S in Industrial Engineering (1966), and Ph.D (1969), all from Lehigh He is a Registered Professional Engineer in Pennsylvania His industrial experience includes several years as a manufacturing engineer with Eastman Kodak Company Since joining Lehigh, he has done consulting, research, and project work for a number of industrial companies His teaching and research areas include manufacturing processes, production systems, automation, material handling, facilities planning, and work systems He has received a number of teaching awards at Lehigh University, as well as the Albert G Holzman Outstanding Educator Award from the Institute of Industrial Engineers (1995) and the SME Education Award from the Society of Manufacturing Engineers (2001) He is a Fellow of IIE (1987) and SME (1996) His publications include over 75 technical articles and eleven books (listed below) His books are used throughout the world and have been translated into French, German, Spanish, Portuguese, Russian, Japanese, Korean, and Chinese The first edition of Fundamentals of Modern Manufacturing received the IIE Joint Publishers Award (1996) and the M Eugene Merchant Manufacturing Textbook Award from the Society of Manufacturing Engineers (1996) PREVIOUS BOOKS BY THE AUTHOR Automation, Production Systems, and Computer-Aided Manufacturing, Prentice Hall, 1980 CAD/CAM: Computer-Aided Design and Manufacturing, Prentice Hall, 1984 (co-authored with E W Zimmers, Jr.) Industrial Robotics: Technology, Programming, and Applications, McGraw-Hill Book Company, 1986 (co-authored with M 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 published by Prentice Hall in 1996, and subsequently published by John Wiley & Sons, Inc., 1999 Automation, Production Systems, and Computer Integrated Manufacturing, Second Edition, Prentice Hall, 2001 Fundamentals of Modern Manufacturing: Materials, Processes, and Systems, Second Edition, John Wiley & Sons, Inc., 2002 Work Systems and the Methods, Measurement, and Management of Work, Pearson Prentice Hall, 2007 Fundamentals of Modern Manufacturing: Materials, Processes, and Systems, Third Edition, John Wiley & Sons, Inc., 2007 Automation, Production Systems, and Computer Integrated Manufacturing, Third Edition, Pearson Prentice Hall, 2008 Fundamentals of Modern Manufacturing: Materials, Processes, and Systems, Fourth Edition, John Wiley & Sons, Inc., 2010 viii BINDEX 08/02/2011 12:14:24 Page 689 Index Clay, 7, 241–243 Cleaning processes, 12, 489–493 Clearance: brazing, 556–557 sheet-metal drawing, 315 sheet-metal shearing, 306–307 CMM, see Coordinate measuring machine CNC, see Numerical control Coated carbides, 410 Coating: carbides, 410, 503 plastic, 166–167 processes, 12, 489, 498–499, 504–507 rubber, 195 wire, 160 Cobalt, 28 Coining, 224, 277, 321 Cold extrusion, 285–286 Cold forming, 256 Cold rolling, 262 Cold welding, 542–543 Cold working, 256–257, 261 Collet, 364 Comminution, 249 Compact discs, 602 Compaction, 220–222, 248–249 Composites: components, 43–44 defined, 7–8, 42 processing, 200–213 properties, 42–44 types, 43–46 Compression molding, 174–175, 195, 207–208 Compression properties, 57–59 Computer-aided process planning, 633–635 Computer integrated manufacturing, 662–664 Computer numerical control, see Numerical control Concentricity, 82 Concurrent engineering, 636–638 Contact lamination, 203 Contact molding, 203 Continuity law, 103–104 Continuous improvement, 635, 661 Continuous laminating, 213 Continuous path, 643 Contour turning, 361 Contouring, 643 Control chart(s), 669–674 Conversion coating, 498–499 Coolants (machining), 418 Coordinate measuring machine, 680–681 Copper, 26 Core (casting), 114–115 Corundum, 30 Cotter pin, 580 Counterboring, 371 Countersinking, 371 Crater wear, 399 Creep feed grinding, 447–448 Crimping, 581 Cross-linking, 36–37, 39, 40 Cross-wire welding, 536 Cubic boron nitride, 32, 411, 434 Cup drawing, 254 Cupola, 130 Curing: adhesives, 564 organic coatings, 506 polymer composites, 206–207, 210 polymers, 39, 41, 175 rubbers, 196, 199–200 Curling, 314 Cutoff, 309, 362, 387 Cutoff length, 85 Cutting: glass, 147 metal, see Machining polymer composites, 213 sheet metal, 305–310 Cutting conditions (machining): defined, 340, 348–349 drilling, 369–370 grinding, 437–438 milling, 376–377 selection of, 422–428 turning, 360–361 Cutting fluid(s), 340, 417–419 Cutting force, see Forces Cutting speed, 338, 423–428 Cutting temperature, 352–354 Cutting tool(s): basic types, 339 costs, 425, 427–428 geometry, see Tool geometry grinding wheels, 434–437 materials, 404–411 technology, 398–417 tool life, 398–403 Cylindrical grinding, 446–447 Cylindricity, 82 Danner process, 145 Dead center, 364 Deburring, 463–464 Deep drawing, 254 Deep grinding, 448 689 BINDEX 08/02/2011 690 12:14:24 Page 690 Index Defects: casting, 133–135 drawing sheet metal, 320 extrusion (plastic), 160–162 extrusion (metal), 293 injection molding, 172 welding, 548–549 Deformation processes: bulk, 253, defined, 9, 10, 252 Density, 72, 237 Depth of cut, 340 Design considerations, see Product design considerations Design for assembly, 581–584, 636–637 Design for assembly, 581–584 Design for manufacturing, 636–637 Desktop machining, 588 Devitrification, 33 Dial indicator, 93 Diamond, 411, 434 Die(s): bar drawing, 298 extrusion (metal), 289–291 extrusion (plastic), 157–160 forging, 279–280 stamping, 323–325 Die casting, 125–127 Die sinking, 376, 463, 467 Die swell, 151 Diffusion, 493, 605 Diffusion welding, 511, 543 Dimensions, 80–81 Dimpling, 581 Dip casting, 196 Dip coating, 505 Dip-pen nanolithography, 618 Direct extrusion, 283–284, 287 Disc grinder, 449 Divider, 90 Doctor blade, 167, 247 Doping, 605 Draft: bar drawing, 294 casting, 137 forging, 280 plastic molding, 188 rolling, 263 Drain casting, 241 Draw bench, 297 Drawing: bar, 253 deep, 254 glass, 145–146 plastic filaments, 166 sheet metal, 254, 314–320 wire, 253 Drawing ratio, 317 Dressing (grinding), 442 Drill bit(s), 369, 415–516 Drill jig, 373 Drill press(es), 369, 371–373 Drilling, 11, 338–339, 363, 369–373 Droplet deposition manufacturing, 591–592 Dry machining, 420 Dry plasma etching, 605 Dry pressing, 243–244 Dry spinning, 166 Drying: ceramics, 244–245 organic coatings, 506 Ductile iron, 23 Ductility, 53–54 EBM, see Electron beam machining ECM, see Electrochemical machining Edge bending, 311 EDM, see Electric discharge machining Elastic limit, 52 Elastic modulus, see Modulus of elasticity Elastic reservoir molding, 207–208 Elastomers: defined, 7, 35, 40 processing technology, 192–200 products, 197–198, 200 properties, 40 types, 40–42 Electric discharge forming, 332 Electric discharge machining, 465–467, 610 Electric discharge wire cutting, 467 Electric furnaces, 131, 141 Electrochemical deburring, 463–464 Electrochemical fabrication, 610 Electrochemical grinding, 464 Electrochemical machining, 461–463 Elecrochemical plating, 494–496 Electroforming, 496–497, 605, 610 Electrogas welding, 528–529 Electrohydraulic forming, 332–333 Electroless plating, 497, 605, 610 Electromagnetic forming, 333 Electron-beam lithography, 616 Electron-beam machining, 468–469, 610 Electron-beam welding, 511, 539–540 Electroplating, 12, 494–496, 605, 610 Elongation, 53 BINDEX 08/02/2011 12:14:24 Page 691 Index Embossing, 321, 581 Encapsulation (plastic), 185 Engine lathe, 363–364 Engineering materials, 6–8, 15–46 Engineering stress-strain, 51–54 Enterprise resource planning, 664 Epoxies, 39 Etchant, 470, 471 Etch factor, 472, 474 Etching, 470, 605 Ethylene-propylene rubber, 41 Eutectic alloys, 106 Evaporative-foam process, 118 Expandable foam molding, 186 Expanded polystyrene process, 118–119 Expansion fit, 12, 578 Expendable mold, 99, 113 Expendable mold casting, 113–122 Expert systems, 634 Explosion welding, 543–544 Explosive forming, 332 Extrusion: cemented carbides, 249 ceramics, 243 metals, 10, 253, 283–293 plastics, 152–162 powdered metals, 226–227 rubber, 194 Extrusion blow molding, 177–178 Face plate, 365 Facing, 361 Fastener(s), 569–576, 581 Faying surfaces, 510 Feed (cutting), 338, 340 Feldspar, 30 Ferrite, 17 Ferritic stainless steel, 20 Ferrous metals, 6, 16 Fiber-reinforced polymers: applications, 46 defined, 45–46 properties, 46 shaping processes, 191, Fibers: defined, 43, 165 glass, 145–146 in composites, 45–46 materials, 46 plastics, 165–166 types, 44 Filament, 145–146, 165, 209 Filament winding, 209–210 Film, plastic, 162–164 Finishing: ceramics, 248 glass, 147 machining, 340 powdered metals, 225 Firing (sintering), 29–30, 245 Fixture, 373, 512, 548 Flakes, 44, 202 Flanging, 314 Flank wear, 399 Flash: die casting, 126 forging, 275, 280 injection molding, 172 Flashless forging, 276–277 Flatness, 82 Flexible manufacturing system(s), 655–659 Flexure test, 60 Float process (glass), 144 Flow curve, 56, 59 Flow line production, 626 Flow stress, 255–256, 273 Fluid properties, 67–69 Fluidity, 67 Fluidized bed, 506 Flux, 524, 527, 529, 557, 561–562 Flux-cored arc welding, 527–528 Fly cutter, 373 Foam, polymers, 185–186 Foam injection molding, 173 Force(s): bar drawing, 295–296 bending sheet metal, 312–313 cutting sheet metal, 308–309 drawing sheet metal, 318 extrusion, 288 forging, 273–274, 276–277 grinding, 439–441 machining, 345–347 powder metals, 221 rolling, 265–267 stretch forming, 330 wire drawing, 295–296 Forge welding, 542 Forging: metals, 10, 253, 271–280 powered metals, 226–227 Forging hammer, 271, 277–278 Forging press, 271, 279 Form milling, 374 Form turning, 362 Forward extrusion, 283 691 BINDEX 08/02/2011 692 12:14:24 Page 692 Index Foundry, 98, 129–133 Fracture stress, 53 Free machining steel, 422 Freezing point, 73 Friction: forging, 275 metal cutting, 344–345, 348 metal extrusion, 284–285, 287–288 metal forming, 258–259 rolling, 264–266 sheet metal drawing, 316 Friction sawing, 387 Friction stir welding, 546 Friction welding, 511, 544–545 Fullerene, 612 Furnaces: brazing, 559 casting, 129–132 electric, 131, 141 glassworking, 141 Fused-deposition modeling, 594 Fusion welding, 510–511, 522–541 Gage blocks, 89–90 Gages and gaging, 89, 93–94 Galvanized steel, 27 Galvanizing, 498 Gang drill, 373 Gas atomization, 217 Gas metal arc welding, 526–527 Gas tungsten arc welding, 529–530 Gear shaper, 384 Geometry: machined parts, 357–360 nontraditional processes, 456, 476 tool, see Tool geometry Glass: chemistry, 33–34, 140–141 defined, 7, 32, 140 fibers, 34, 145–146 product design, products, 33–34 properties, 33, 141 shaping processes, 141–146 Glass-ceramics, 29, 34–35 Glassworking, 140–147 Glazing, 245 Gray cast iron, 22–23 Grinding, 11, 249–251, 433–450 Grinding fluids, 444 Grinding ratio, 442 Grinding wheels, 434–437 Gross domestic product, Group technology, 626, 651, 655 Guerin process, 322–323 Hacksaw, 387 Hand lay-up, 204–205 Hand modeling, 242 Hand molding, 242 Hand throwing, 242 Hardenability, 484–485 Hardness: cutting tool materials, 404 defined, 62 materials, 64–65 tests, 62–64 Heading, 280–281 Heat-affected zone, 520 Heat of fusion, 73 Heat treatment: castings, 133 ceramics, 12, 245, 247–248 glass, 12, 146–147 metals, 12, 16, 480–487 powdered metals, 12, 225 Hemming, 314 High-energy-rate forming, 332–333 High speed machining, 387–388 High speed steel, 21, 406–407, 413 High strength low-alloy steel, 19 Honing, 450–451 Hooke’s Law, 52, 70 Hot dipping, 497–498 Hot extrusion, 285 Hot hardness, 66–67 Hot pressing, 227, 246, 249 Hot pressure welding, 543 Hot rolling, 262 Hot-runner mold, 171 Hot working, 67, 257–258, 261 Hubbing, 281–282 Hydroforming, 323 Hydrostatic extrusion, 291–292 Impact extrusion, 285, 291 Impact grinding, 241 Impregnation, 224–225 Impression-die forging, 275–276 Incremental positioning, 643 Indirect extrusion, 284–285, 287 Induction heating, 131–132 Industries, 3–4 Infiltration, 225 Injection blow molding, 179 Injection molding, 167–174, 195, 208 BINDEX 08/02/2011 12:14:24 Page 693 Index Ink-jet printing heads, 601 Inserts: cutting tool, 414–415 molding, 580–581 screw thread, 572 Inspection: casting, 135 defined, 678 instruments and gages, 89–96 principles, 678–680 technologies, 680–684 welding, 549–550 Integral fasteners, 581 Interference fit(s), 576–579 Interpolation, 643 Investment casting, 119–121 Ion implantation, 493–494, 605 Ion plating, 501 Iron, 17, 28 Iron-carbon alloy system, 17 Ironing, 321 ISO 9000, 677–678 Isostatic pressing, 225–226, 246–247, 249 Isothermal extrusion, 285 Isothermal forging, 282–283 Isothermal forming, 258 Laser-beam machining, 469–470, 610 Laser-beam welding, 511, 540 Laser evaporation method, 616–617 Lathe, 363–366 Lay (in surface texture), 84 Layer processes, 604–607, 620 Lean production, 659–662 Lehr, 147 Lift-off technique, 607 LIGA process, 607–608 Limit dimensions, 81 Line balancing, 631 Liquid-metal forging, 127 Liquid phase sintering, 228 Liquidus, 73, 105 Lithography, 605 Live center, 364 Lost-foam process, 118 Lost pattern process, 118 Lost-wax process, 119 Low-pressure casting, 124 Lubricants and lubrication: ceramics, 246 metal cutting, 348, 418–419 metal forming, 259 powdered metals, 220 Jig, 373 Jig grinder, 449 Jiggering, 242–243 Job shop, 624 Joining, 509 Joint(s): adhesive bonded, 564–565 bolted, 573–575 brazed, 555–557 soldered, 560 weld, 513–515, 519–520, 549 Jolleying, 243 Jominy end-quench test, 485 Just-in-time, 660–661 Machinability, 393–394, 420–422 Machine cell(s), 653–655 Machine tools: defined, 12–13, 340–341 drilling, 371–373 machining centers, 380–381, 650 milling, 378–380 plastic extrusion, 152–154 plastic molding, 167–168 presses, see Presses turning and boring, 363–369 Machine vision, 681–684 Machine welding, 512 Machining: advantages and disadvantages, 337 defined, 11, 336 economics, 422–428 high speed, 387–388 machine tools, see Machine tools operations, 338–339, 357–387 part geometry, 357–360 powder metallurgy, 224 product design considerations, 392–394 theory, 336–354 Machining center, 380–381, 650 Machining economics, 422–428 Kanban, 660 Kaolinite, 29 Kevlar, 38, 46, 201 Kiln, 245 Knoop hardness, 64 Knurling, 363 Ladles (casting), 132 Laminated-object manufacturing, 593–594 Lancing, 322, 581 Lapping, 451–452 693 BINDEX 08/02/2011 694 12:14:24 Page 694 Index Magnesium, 25 Magnetic pulse forming, 333 Make or buy decision, 632–633 Malleable iron, 23 Manganese, 19 Mannesmann process, 270 Manual data input, 650 Manufactured products, see Products, manufactured Manufacturing (general), 1, 2, 15 Manufacturing capability, Manufacturing engineering, 627 Manufacturing industries, 1, Manufacturing processes, classification of, 8–12, 628–629 Manufacturing support systems, 626–627 Manufacturing systems, 624, 640 Maraging steel, 485 Martensite, 481–484 Martensitic stainless steel, 20–21 Masks and masking, 470–471 Mass finishing, 492–493 Mass production, 626 Material-addition RP, 588 Material removal processes, 9, 10–12, 336 Materials, engineering, see Engineering materials Materials in manufacturing, 6–8 Measurement: conventional instruments, 89–94 cutting temperatures, 353–354 defined, 89 surfaces, 94–96 Mechanical assembly, 12, 569–584 Mechanical cleaning, 491–493 Mechanical properties: hardness, 62–66 stress-strain relationships, 50–62 temperature effect, 66–67 Mechanical thermoforming, 184 Melamine formaldehyde, 39 Melt fracture, 160 Melt spinning, 165–166 Melting point, 73 MEMS, 599 Merchant equation, 347–350 Mesh count, 234–235 Metal cutting, see Machining Metal forming, 252–259 Metal injection molding, 226 Metal matrix composites, 43, 45 Metals, 6–7, 16–28 Micro-contact printing, 609, 616 Microelectromechanical systems, 599 Microfabrication, 603–611 Micro-imprint lithography, 609, 616 Micromachining, 606 Micrometer, 91–93 Microsensors, 600 Microstereolithography, 611 Microsystems, 599, 601–603 MIG welding, 527 Milling, 11, 339, 373–380 Milling cutters, 416–417 Milling machine(s), 373, 378–380 Mill-turn center, 381 Modulus of elasticity, 52, 61, 70 Mold(s): casting, 98–100, 115–122 plastic injection, 168–171 polymer matrix composites, 203–208 thermoforming, 182–184 Molding: compression molding, 174–175, 207–208 injection, 167–174, 208 polymer matrix composites, 203–208 rubber, 195–196 tires, 199–200 transfer molding, 176–177, 208 Molding compounds, 202–203, 207 Molding inserts, 580–581 Molybdenum, 19, 407 Mond process, 502 Monolayer, 620 Multifunction machine, 383 Multitasking machine, 383 Mushy zone, 105 Nanofabrication processes, 615–620 Nano-imprint lithography, 616 Nanoscience, 599 Nanotechnology, 599, 611–613 Nanotubes, 612–613 Natural rubber, 40–41, 192–193 Natural tolerance limits, 669 NC, see Numerical control Near net shape, 12, 98, 216, 261, 276 Necking, 53, 55, 59 Neoprene, 41 Net shape, 12, 35, 98, 149, 216, 261, 276 Newtonian fluid, 68, 150–151 Nickel, 19, 26, 28 Nitride ceramics, 7, 32 Nitriding, 487, 493 Noncrystalline structures, Nonferrous metals, 7, 16, 23–28 Nontraditional processes, 11, 336, 456–476 Normalizing, 481 Notching, 310 BINDEX 08/02/2011 12:14:24 Page 695 Index Numerical control: applications, 650–651 definition, 640–641 drilling, 373 filament winding, 210 machining center, 380–381, 650 milling, 380 part programming, 641, 648–650 punch press, 326 tape-laying, 206 technology, 641–650 turning, 366, 381 Nut(s), 570 Nylon, 38 Open-back inclinable, 326 Open-die forging, 271–275 Open mold, 99, 201, 203–207 Operation sheet, 631 Optical encoder, 647 Organic coating, 504–507 Orthogonal cutting, 341–343, 347–348 Oxide ceramics, 31 Oxyacetylene welding, 537–538 Oxyfuel gas welding, 511, 537–539 Packing factor (powders), 237 Painting, 12, 504 Parallelism, 82 Part family, 651–653 Part geometry (machining), 357–360 Part programming, NC, 648–650 Particles, 44, 202 Particulate processing, 9–10, 215 Parting, 309 Parts classification and coding, 652 Pattern (casting), 100, 114–115 Pearlite, 482 Perforating, 310 Permanent mold, 100 Permanent mold casting, 122–129 Perpendicularity, 82 Phase(s): defined, in composites, 7, 43–44, 201–202 in steel, 17 Phase diagrams: copper-nickel, 105 iron-carbon, 17, 20 WC-Co, 249 Phenol-formaldehyde, 40 Phenolics, 40 Phosphate coating, 498 Photochemical machining, 474, 610 Photoresist, 471 Physical properties, 72–76 Physical vapor deposition, 12, 499–501, 605 Piping (extrusion), 293 Planing, 384 Plant capacity, Plant layout, 624–626 Plasma arc welding, 530–531 Plaster-mold casting, 121–122 Plastic deformation, 305 Plastic forming, 242 Plastic pressing, 243 Plastics, see Polymers Plating processes, 494–498 Pointing (drawing), 299 Point-to-point, 642–643 Polishing, 452–453 Polyamides, 38 Polybutadiene, 41 Polycarbonate, 38 Polyesters, 38, 40 Polyethylene, 38 Polyethylene terephthalate, 38 Polymer matrix composites: defined, 7, 45–46 processing, 191, 203–213 starting materials, 201–203 Polymer melt, 71, 150–152, 154 Polymer(s): categories, 7, 35 composites, see Polymer matrix composites defined, 7, 35 product design considerations, 186–188 products, 149–150 properties, 35–36, 65 rubbers, see Elastomers shape processing, 149–186 structures, 36–38 thermoplastics, see Thermoplastic polymers thermosets, see Thermosetting polymers Polymethylmethacrylate, 38 Polypropylene, 38 Polystyrene, 39, 44, 186 Polyurethanes, 40, 42, 186 Polyvinylchloride, 39 Porosity (metal powders), 237 Positioning systems, 642–648 Potter’s wheel, 242 Powder coating, 506–507 Powder injection molding, 226, 247 Powder metallurgy, 16, 215–231 Powders, 234–237 695 BINDEX 08/02/2011 696 12:14:24 Page 696 Index Power: arc welding, 524–525 extrusion, 288 machining, 350–352 resistance welding, 531–532 rolling, 266–267 Power density (welding), 516–517, 539 Precipitation hardening, 485–486 Precision, defined, 89 Precision forging, 276–277 Precision gage blocks, 89–90 Preform molding, 207 Prepreg, 203–204, 209 Press(es): drill, 371–373 extrusion (metal), 291 forging, 279 stamping, 304, 325–329 Press-and-blow, 143 Press brake, 326 Press fitting, 12, 576–578 Pressing: ceramics, 243–244, 246–247 glass, 142 powder metallurgy, 215, 220–222 Pressure thermoforming, 182–184 Pressworking, 253 Process capability, 668–669 Process planning, 627–635 Processes, manufacturing, classification of, 8–12 Product design considerations: assembly, 581–584 casting, 137–138 ceramics, 250 design for manufacturing, 637 glass, 147–148 machining, 392–394 plastics, 186–188 powder metallurgy, 229–231 welding, 550–551 Product variety, Products, manufactured, 2, Production capacity, Production flow analysis, 652 Production line, 626 Production planning and control, 627 Production quantity, 4–5, 633 Production systems, 623–627 Properties: fluid, see Fluid properties general, 49–50 mechanical, see Mechanical properties physical, see Physical properties Property-enhancing processes, 12 Protractor, 94 Pseudoplastic, 69, 151 Pulforming, 211–212 Pultrusion, 210–211 Punch-and-die, 254, 304 Punching, 306 Quality: casting, 133–135 defined, 667–668 plastic extrusion, 160–161 plastic injection molding, 172 programs, 674–678 weld, 547–550 Quality control, 627, 667 Quantity, production, see Production quantity Quartz, 30, 140 Quenching, 484–485 Rack plating, 496 Radial drill, 371–373 Radial forging, 281 Rake angle, 339, 412 Rapid prototyping, 587–597 Rapid tool making, 596 Reaction injection molding, 173–174, 186, 208 Reaming, 363, 371 Recrystallization, 67, 258, 481 Recrystallization temperature, 67 Redrawing, 319 Reduction: bar drawing, 294, 296–297 deep drawing, 317 extrusion, 286 rolling, 263 Reflow soldering, 563 Refractory ceramics, 30 Reinforcing agents, 46, 201–202 Relief angle, 339 Resin transfer molding, 208 Resistance projection welding, 535–536 Resistance welding, 511, 531–536 Retaining ring, 578–579 Reverse drawing, 319 Reverse extrusion, 284 Rheocasting, 128 Ring rolling, 269 Riser (casting), 99–100, 109–110 Rivet(s), 12, 575–576 Robotic welding, 513 Rockwell hardness, 63–64 Roll bending, 330–331 BINDEX 08/02/2011 12:14:24 Page 697 Index Roll coating, 567 Roll forming, 330–331 Roll piercing, 270 Roll welding, 543 Roller mill, 241 Rolling: gear, 270 glass, 144 metals, 253, 262–269 powdered metals, 226–227 ring, 269 thread, 269 Rolling mills, 267–269 Rotary tube piercing, 270 Rotational molding, 180–181 Rotomolding, 180 Roughing, 340 Roughness, surface, see Surface roughness Roundness, 82 Route sheet, 630–631 Rubber, see Elastomers Rubber forming processes, 322–323 Rule, steel, 90 Sand blasting, 491 Sand casting, 100, 113–117 Sawing, 386–387 Scanning probe microscopes, 614–615, 617–618 Scanning tunneling microscope, 614 Screen resist, 471 Screw(s), 570–572 Screw thread inserts, 572 Seam welding, 514, 534–535 Seaming, 314, 581 Selective laser sintering, 594–595 Self-assembly, 618–620 Semi-dry pressing, 243 Seminotching, 310 Semipermanent-mold casting, 122 Semisolid metal casting, 127–128 Setup reduction, 662 Sewing, 580 Shape factor: extrusion (metal), 289–291 extrusion (plastic), 157 forging, 273, 276 Shape rolling, 267 Shaping, 383–384 Shaping processes, 8–12 Sharkskin, 161 Shear angle, 308, 341–342, 348 Shear modulus, 61 Shear plane, 341 Shear properties, 60–62 Shear strength, 62 Shearing, 254–255, 306 Sheet: metal, 262–263, 304 metalworking, 253–255, 304–333 plastic, 162–164 Shell molding, 117–118 Shielded metal arc welding, 525–526 Shot peening, 492 Shrink fit, 578 Shrinkage: casting, 107–108 ceramics, 244, 250 plastic molding, 171–172 Sialon, 411 Silica, 7, 29–30, 33, 140 Silicon carbide, 7, 30, 434 Silicon nitride, 32 Silicon processing, 604–607 Siliconizing, 493 Simultaneous engineering, 638 Single-point tool(s), 339 Sintered carbides, 408 Sintered polycrystalline diamond, 411 Sintering: cemented carbides, 249 ceramics, 245, 247–248 liquid phase, 228 metal powders, 215–216, 222–224 Six sigma, 675–677 Size effect, 351–351, 440 Slab, 262 Slip casting, 241–242 Slit-die extrusion, 162–163 Slotting, 310, 374, 387 Slush casting, 124 Snag grinder, 449 Snap fit, 578 Snap ring, 578–579 Soaking, 262, 481 Soft lithography, 608–609, 616 Soldering, 12, 560–563 Solid ground curing, 591 Solid-state welding, 511, 522, 541–547 Solidification time (casting), 104–107, 109 Solidification processes: casting, 9, 98–100, 113–129 defined, 9, 97 glassworking, 140–146 plastics, 149–186 polymer-matrix composites, 200–213 697 BINDEX 08/02/2011 698 12:14:24 Page 698 Index Solidus, 73, 105 Spark sintering, 227–228 Specific energy (machining), 350–351 Specific gravity, 72 Specific heat, 75, 101 Speed lathe, 365 Spinning: glass, 142 plastics, 165–166 sheet metal, 331–332 Spot facing, 371 Spot welding, 514, 533–534 Spraying (coating), 167, 505 Spray-up, 205–206 Springback, 312 Sputtering, 500–501 Squareness, 82 Squeeze casting, 127 Stainless steel, 19–21, 26 Stamping, 254, 304 Stapling, 580 Statistical process control, 669–674 Steel(s): defined, 6, 17–18 for casting, 136 high speed, see High speed steel low alloy, 19 plain carbon, 18–19 stainless, 19–21 tool, 21–22 Stepping motor, 644–646 Stereolithography, 590–591, 611 Stick welding, 525 Sticking (friction), 259, 264 Stitching, 579–580 Straightness, 82 Strain: defined, 52, 54–55, 57, 60 metal extrusion, 286–287 metal forging, 272 metal machining, 342 rolling, 264 wire and bar drawing, 295–296 Strain hardening, 55 Strain hardening exponent, 56 Strength coefficient, 56 Strength-to-weight ratio, 42, 46, 72 Stress-strain relationship: compression, 57–59 shear, 60–62 tensile, 50–57 types of, 56–57 Stretch blow molding, 179–180 Stretch forming, 330 Structural foam molding, 173, 186 Stud(s), 572 Styrene-butadiene rubber, 42 Submerged arc welding, 529 Super alloys, 28 Supercooled liquid, 73 Superfinishing, 452 Superheat (casting), 101 Surface finish, see Surface roughness Surface grinding, 444–445 Surface hardening, 487 Surface integrity, 83–85, 96 Surface micromachining, 606 Surface plate, 90 Surface processing, 12, 489–507 Surface roughness: abrasive processes, 450 casting, 137 defined, 83–85 grinding, 438–439 machining, 389–393 measurement of, 95–96 manufacturing processes, 87 Surface technology, 82 Surface texture, 83–85 Surface treatments, 12, 489–507 Surfaces, 80–83 Surfacing weld, 515 Swaging, 281 Swell ratio (polymers), 152 Synthetic rubber, 41–42, 193 Systems, production, 623–627 Tantalum carbide, 31 Tape-laying machines, 206 Taper turning, 361 Tapping, 371 Taylor tool life equation, 400–403, 424–426 Technological processing capability, 5–6 Technology (defined), Temperature: effect on properties, 66–67, 73 grinding, 441 machining, 352–354 metal forming, 256–258 Tempering: glass, 147 steel, 484 Tensile strength, 23, 53 Tensile test, 50–54 Testing: hardness, 62–64 BINDEX 08/02/2011 12:14:24 Page 699 Index inspection, 678 tensile, 50–54 torsion, 61–62 welds, 549–550 Thermal energy processes, 464–470 Thermal oxidation, 605 Thermal properties: conductivity, 75 diffusivity, 75 expansion, 72–73 in manufacturing, 76 in metal cutting, 352–353 specific heat, 74–75 Thermit welding, 540–541 Thermoforming, 181–184 Thermoplastic elastomers, 42, 200 Thermoplastic polymers: defined, 7, 37, 150 important thermoplastics, 37–39 properties, 37, 42 shaping processes, 152–172, 177–185 Thermosetting polymers: defined, 7, 39, 150 important thermosets, 39–40 properties, 39 shaping processes, 173–177, 185 Thin-film magnetic heads, 602 Thixocasting, 128 Thixomolding, 128 Threaded fasteners, 12, 570–575 Threading, 362 Thread rolling, 269 Three-dimensional printing, 595–596 Three-plate mold, 170–171 Through hole, 369 TIG welding, 529 Time-temperature-transformation curve, 482–483 Time, machining: drilling, 369–370 electrochemical machining, 462–463 milling, 377 minimizing, 423–424 turning, 360–361 Tinning, 497, 560 Tires, 197–200 Titanium, 26–27 Titanium carbide, 31, 45, 409–410 Titanium nitride, 32, 409–410 Tolerance(s): casting, 137–138 defined, 80–81 machining, 388–389, 393 manufacturing processes, 86 natural tolerance limits, 669 plastic molding, 188 Tool-chip thermocouple, 353–354 Tool geometry: effect on surface roughness, 390 milling cutters, 416–417 multiple-cutting edge, 339, 415–417 orthogonal cutting, 342 single-point, 339, 412–415 twist drill, 415–516 Tool grinders, 449 Tooling, general, 13 Tool life (machining), 400–403 Tool, machine, see Machine tool Tool steels, 21–22 Tool wear (machining), 399–400 Tools, see Cutting tools or Dies Torque-turn tightening, 575 Torque wrench, 575 Torsion test, 60 Total productive maintenance, 662 Total quality management, 674–675 Total solidification time, 104, 106–107, 109 Transfer molding, 176–177, 195, 208 Transverse rupture strength, 60, 405 Trimming, 133, 283, 310 True stress-strain, 54–56 Truing (grinding), 442 TTT curve, 482–483 Tube rolling, 212 Tumbling, 492–493 Tungsten, 407 Tungsten carbide: cutting tools, 408–409 general, 31–32, 45 processing of, 248–250 Tunneling, 614 Turning, 11, 338, 360–369 Turning center, 381 Turret drill, 373 Turret lathe, 365 Turret press, 326 Twist drill, 415–516 Twisting, 322 Two-plate mold, 168–170 Two-roll mill, 194 Ultimate tensile strength, 53 Ultra-high precision machining, 610 Ultrasonic inspection, 684 Ultrasonic machining, 457–458, 610 Ultrasonic welding, 511, 546–547 Undercut, 472, 475 699 BINDEX 08/02/2011 700 12:14:25 Page 700 Index Unilateral tolerance, 81 Unit operation, Unit power (machining), 350–351 Upset forging, 280 Upsetting, 280–281 Urea formaldehyde, 39 V-bending, 311 Vacuum evaporation, 500 Vacuum forming, 181 Vacuum permanent-mold casting, 124 Vacuum thermoforming, 181–182 Vanadium, 19, 407 Vapor degreasing, 491 Vapor deposition processes, 499–504 Vernier caliper, 91 Vibratory finishing, 492 Vickers hardness, 63–64 Viscoelasticity, 69–71, 151–152 Viscosity, 67–69, 150–151, 155 Vision, machine, 681–684 Vitreous, 29, 34 Volumetric specific heat, 75 Vulcanization, 40, 191, 196–197 Warm working, 257, 261 Washer, 572 Water atomization, 217 Water jet cutting, 458–459 Wave soldering, 563 Waviness (in surface texture), 83 Wear: cutting tool, 399–400 grinding wheel, 441–443 Weldbonding, 565 Weld joints, 513–515, 519–520, 549 Welding: defects, 548–549 definition and overview, 509–513 design considerations, 550–551 joints, 513–515, 519–520 physics, 515–519 processes, 510–511, 522–547 quality, 547–550 Wet chemical etching, 605 Wet lay-up, 204 Wet spinning, 166 White cast iron, 23 Windshields (automobile), 147 Wire and cable coating, 160 Wire drawing, 293–299 Wire EDM, 467, 610 Work hardening, 55 Work holding: boring, 367–368 drilling, 373 turning, 364–365 Wrought metal, 16 X-ray inspection, 684 X-ray lithography, 616 Yield point, 52 Yield strength, 52 Zinc, 27–28 BINDEX 08/02/2011 12:14:25 Page 701 BENDP 06/21/2011 14:42:19 Page 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 Multiplier Example units (and symbols) nanomicromillicentikilomegagiga- n m m c k M G 10
9 10
6 10
3 10
2 103 106 109 nanometer (nm) micrometer, micron (mm) millimeter (mm) centimeter (cm) kilometer (km) megaPascal (MPa) gigaPascal (GPa) Table of Equivalencies between USCS and SI units: Variable SI units USCS units Equivalencies Length meter (m) Area m2, mm2 inch (in) foot (ft) yard mile micro-inch (m-in) in2, ft2 Volume m3, mm3 in3, ft3 Mass kilogram (kg) Density kg/m3 Velocity Acceleration Force Torque m/min m/s m/s2 Newton (N) N-m pound (lb) ton lb/in3 lb/ft3 ft/min in/min ft/sec2 pound (lb) ft-lb, in-lb Pressure Stress Energy, work Pascal (Pa) Pascal (Pa) Joule (J) lb/in2 lb/in2 ft-lb, in-lb Heat energy Power Joule (J) Watt (W) British thermal unit (Btu) Horsepower (hp) Specific heat Thermal conductivity Thermal expansion Viscosity J/kg- C J/s-mm- C (mm/mm)/ C Pa-s Btu/lb- F Btu/hr-in - F (in/in)/ F lb-sec/in2 1.0 in ¼ 25.4 mm ¼ 0.0254 m 1.0 ft ¼ 12.0 in ¼ 0.3048 m ¼ 304.8 mm 1.0 yard ¼ 3.0 ft ¼ 0.9144 m ¼ 914.4 mm 1.0 mile ¼ 5280 ft ¼ 1609.34 m ¼ 1.60934 km 1.0 m-in ¼ 1.0  10
6 in ¼ 25.4  10
3 mm 1.0 in2 ¼ 645.16 mm2 1.0 ft2 ¼ 144 in2 ¼ 92.90  10
3 m2 1.0 in3 ¼ 16,387 mm3 1.0 ft2 ¼ 1728 in3 ¼ 2.8317  10
2 m3 1.0 lb ¼ 0.4536 kg 1.0 ton (short) ¼ 2,000 lb ¼ 907.2 kg 1.0 lb/in3 ¼ 27.68  103 kg/m3 1.0 lb/ft3 ¼ 16.0184 kg/m3 1.0 ft/min ¼ 0.3048 m/min ¼ 5.08  10
3 m/s 1.0 in/min ¼ 25.4 mm/min ¼ 0.42333 mm/s 1.0 ft/sec ¼ 0.3048 m/s2 1.0 lb ¼ 4.4482 N 1.0 ft-lb ¼ 12.0 in-lb ¼ 1.356 N-m 1.0 in-lb ¼ 0.113 N-m 1.0 lb/in2 ¼ 6895 N/m2 ¼ 6895 Pa 1.0 lb/in2 ¼ 6.895  10
3 N/mm2 ¼ 6.895  10
3 MPa 1.0 ft-lb ¼ 1.356 N-m ¼ 1.356 J 1.0 in-lb ¼ 0.113 N-m ¼ 0.113 J 1.0 Btu ¼ 1055 J 1.0 hp ¼ 33,000 ft-lb/min ¼ 745.7 J/s ¼ 745.7 W 1.0 ft-lb/min ¼ 2.2597  10
2 J/s ¼ 2.2597  10
2 W 1.0 Btu/lb- F ¼ 1.0 Calorie/g- C ¼ 4,187 J/kg- C 1.0 Btu/hr-in - F ¼ 2.077  10
2 J/s-mm- C 1.0 (in/in)/ F ¼ 1.8 (mm/mm)/ C 1.0 lb-sec/in2 ¼ 6895 Pa-s ¼ 6895 N-s/m2 BENDP 06/21/2011 14:42:19 Page 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 ¼ 3.25 in to its equivalent value in millimeters Solution: The corresponding equivalency statement is: 1.0 in ¼ 25.4 mm L ¼ 3.25 in x (25.4 mm/in) ¼ 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 ¼ 1000 mm2 to its equivalent in square inches Solution: The corresponding equivalency statement is: 1.0 in2 ¼ 645.16 mm2 A ¼ 1000 mm2/(645.16 mm2/in2) ¼ 1.55 in2