DeGarmo's Materials and Processes in Manufacturing

Höfundar: Ronald A. Kohser; Peter C. Collins; J. T. Black (Útgáfa: 14)
DeGarmo's Materials and Processes in Manufacturing

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Classic textbook introducing key concepts in manufacturing with a focus on practical applications, updated to include the latest industry developments. For over 65 years, DeGarmo’s Materials and Processes in Manufacturing has comprehensively presented both traditional and new manufacturing materials, processes, and systems in a descriptive, non-mathematical manner. Students are first introduced to a range of engineering materials, including metals, plastics and polymers, ceramics, and composites.

The processes used to convert this “stuff” into “things” are then described, along with their typical applications, capabilities, and limitations. Segments cover casting, forming, machining, welding and joining, and additive manufacturing. Supporting chapters present concepts relating to material selection, heat treatment, surface finishing, measurement, inspection, and manufacturing systems.

The Fourteenth Edition has been updated to reflect the most current technologies. Coverage of additive manufacturing (3D printing) has been significantly expanded, along with updates on new and advanced materials. Case studies are featured throughout the book and review problems have been placed at the end of each chapter. A full collection of online bonus material is provided for both students and instructors.

DeGarmo’s Materials and Processes in Manufacturing, Fourteenth Edition includes information on: Equilibrium phase diagrams and the iron-carbon system, heat treatment, and process capability and quality controlExpendable-mold and multiple-use-mold casting processes, powder metallurgy (particulate processing), fundamentals of metal forming, and bulk-forming and sheet-forming processesCutting tool materials, turning and boring processes, milling, drilling and related hole-making processes, and CNC processes and adaptive control in the A(4) and A(5) levels of automationSawing, broaching, shaping, and filing machining processes, thread and gear manufacturing, and surface integrity and finishing processes DeGarmo’s Materials and Processes in Manufacturing has long set the standard for introducing students to the materials and processes in product manufacturing, and has been incorporated in programs of manufacturing, mechanical, industrial, metallurgical, and materials engineering, as well as various technology degrees.

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Útgefandi
Wiley Global Research (STMS)
ISBN
9781394173075
Print ISBN
9781394173051
Format
ePub
Útgáfa
14
Höfundar
Ronald A. Kohser; Peter C. Collins; J. T. Black
Tungumál
English
Útgefið
2024-12-31
Prent takmörkun á líftíma
100
Prent takmörkun
10
Afritunar takmörkun
2

Kaflar

  • Cover
  • Table of Contents
  • Title Page
  • Copyright
  • Preface
  • History of the Text
  • Purpose of the Book
  • Organization of the Book
  • Supplements
  • Acknowledgments
  • About the Authors
  • About the Cover
  • Acronyms
  • CHAPTER 1: Introduction to DeGarmo’s Materials and Processes in Manufacturing
  • 1.1 Materials, Manufacturing, and the Standard of Living
  • 1.2 Manufacturing and Production Systems
  • Review Questions
  • Problems
  • CHAPTER 2: Properties of Materials
  • 2.1 Introduction
  • 2.2 Static Properties
  • 2.3 Dynamic Properties
  • 2.4 Temperature Effects (Both High and Low)
  • 2.5 Machinability, Formability, and Weldability
  • 2.6 Fracture Toughness and the Fracture Mechanics Approach
  • 2.7 Physical Properties
  • 2.8 Testing Standards and Testing Concerns
  • Key Words
  • Review Questions
  • Problems
  • CASE STUDY Separation of Mixed Materials
  • CASE STUDY Overhead Conveyor for Meat Processing
  • Notes
  • CHAPTER 3: Nature of Materials
  • 3.1 Structure—Property—Processing—Performance Relationships
  • 3.2 The Structure of Atoms
  • 3.3 Atomic Bonding
  • 3.4 Secondary Bonds
  • 3.5 Atom Arrangements in Materials
  • 3.6 Crystal Structures
  • 3.7 Development of a Grain Structure
  • 3.8 Elastic Deformation
  • 3.9 Plastic Deformation
  • 3.10 Dislocation Theory of Slip
  • 3.11 Strain Hardening or Work Hardening
  • 3.12 Plastic Deformation in Polycrystalline Material
  • 3.13 Grain Shape and Anisotropic Properties
  • 3.14 Fracture
  • 3.15 Cold Working, Recrystallization, and Hot Working
  • 3.16 Grain Growth
  • 3.17 Alloys and Alloy Types
  • 3.18 Atomic Structure and Electrical Properties
  • Key Words
  • Review Questions
  • Problems
  • Notes
  • CHAPTER 4: Equilibrium Phase Diagrams and the Iron–Carbon System
  • 4.1 Introduction
  • 4.2 Phases
  • 4.3 Equilibrium Phase Diagrams
  • 4.4 Iron–Carbon Equilibrium Diagram
  • 4.5 Steels and the Simplified Iron–Carbon Diagram
  • 4.6 Cast Irons
  • Key Words
  • Review Questions
  • Problems
  • CASE STUDY Fish Hooks
  • Notes
  • CHAPTER 5: Heat Treatment
  • 5.1 Introduction
  • 5.2 Processing Heat Treatments
  • 5.3 Heat Treatments Used to Increase Strength
  • 5.4 Strengthening Heat Treatments for Nonferrous Metals
  • 5.5 Strengthening Heat Treatments for Steel
  • 5.6 Surface Hardening of Steel
  • 5.7 Furnaces
  • 5.8 Heat Treatment and Energy
  • Key Words
  • Review Questions
  • Problems
  • CASE STUDY A Carpenter’s Claw Hammer
  • CASE STUDY A Flying Chip from a Sledgehammer
  • Notes
  • CHAPTER 6: Ferrous Metals and Alloys
  • 6.1 Introduction To History-Dependent Materials
  • 6.2 Ferrous Metals
  • 6.3 Iron
  • 6.4 Steel
  • 6.5 Stainless Steels
  • 6.6 Tool Steels
  • 6.7 Cast Irons
  • 6.8 Cast Steels
  • 6.9 The Role of Processing on Cast Properties
  • Key words
  • Review Questions
  • Problems
  • CASE STUDY The Paper Clip
  • Notes
  • CHAPTER 7: Nonferrous Metals and Alloys
  • 7.1 Introduction
  • 7.2 Copper and Copper Alloys
  • 7.3 Aluminum and Aluminum Alloys
  • 7.4 Magnesium and Magnesium Alloys
  • 7.5 Zinc and Zinc Alloys
  • 7.6 Titanium and Titanium Alloys
  • 7.7 Nickel-Based Alloys
  • 7.8 Superalloys, Refractory Metals, and Other Materials Designed for High-Temperature Service
  • 7.9 Lead and Tin and Their Alloys
  • 7.10 Some Lesser-Known Metals and Alloys
  • 7.11 Metallic Glasses
  • 7.12 Graphite
  • 7.13 Materials for Specific Applications
  • 7.14 High Entropy Alloys
  • Key Words
  • Review Questions
  • Problems
  • CASE STUDY Hip Replacement Prosthetics
  • CASE STUDY Replacement US Coinage
  • Notes
  • CHAPTER 8: Nonmetallic Materials: Plastics,* Elastomers,** Ceramics, and Composites
  • 8.1 Introduction
  • 8.2 Plastics
  • 8.3 Elastomers
  • 8.4 Ceramics
  • 8.5 Composite Materials
  • Key Words
  • Review Questions
  • Problems
  • CASE STUDY Lightweight Armor and Protective Helmets
  • Notes
  • CHAPTER 9: Material Selection
  • 9.1 Introduction
  • 9.2 Material Selection and Manufacturing Processes
  • 9.3 The Design Process
  • 9.4 Approaches to Material Selection
  • 9.5 Additional Factors to Consider
  • 9.6 Consideration of the Manufacturing Process
  • 9.7 Ultimate Objective
  • 9.8 Material Substitution
  • 9.9 Effect of Product Liability on Materials Selection
  • 9.10 Aids to Material Selection
  • Key Words
  • Review Questions
  • Problems
  • CASE STUDY Material Selection
  • Notes
  • CHAPTER 10: Measurement and Inspection
  • 10.1 Introduction
  • 10.2 Standards of Measurement
  • 10.3 Allowance and Tolerance
  • 10.4 Inspection Methods for Measurement
  • 10.5 Measuring Instruments
  • 10.6 Vision Systems
  • 10.7 Coordinate Measuring Machines
  • 10.8 Angle-Measuring Instruments
  • 10.9 Gages for Attributes Measuring
  • Key Words
  • Review Questions
  • Problems
  • CASE STUDY Measuring an Angle
  • CHAPTER 11: Nondestructive Evaluation (NDE)/Nondestructive Testing (NDT)
  • 11.1 Destructive Versus Nondestructive Testing
  • 11.2 Visual Inspection
  • 11.3 Liquid Penetrant Inspection
  • 11.4 Magnetic Particle Inspection
  • 11.5 Ultrasonic Inspection
  • 11.6 Radiography
  • 11.7 Eddy-Current Testing
  • 11.8 Acoustic Emission Monitoring
  • 11.9 Other Methods of Nondestructive Testing and Inspection
  • 11.10 Dormant Versus Critical Flaws
  • 11.11 Current and Future Trends
  • Review Questions
  • Problems
  • CHAPTER 12: Process Capability and Quality Control
  • 12.1 Introduction
  • 12.2 Determining Process Capability
  • 12.3 Introduction to Statistical Quality Control
  • 12.4 Sampling Errors
  • 12.5 Gage Capability
  • 12.6 Just in Time/Total Quality Control
  • 12.7 Six Sigma
  • 12.8 Summary
  • Key Words
  • Review Questions
  • Problems
  • CHAPTER 13: Fundamentals of Casting
  • 13.1 Introduction to Materials Processing
  • 13.2 Introduction to Casting
  • 13.3 Casting Terminology
  • 13.4 The Solidification Process
  • 13.5 Patterns
  • 13.6 Design Considerations in Castings
  • 13.7 The Casting Industry
  • Key Words
  • Review Questions
  • Problems
  • CASE STUDY The Cast Oil-Field Fitting
  • Note
  • CHAPTER 14: Expendable-Mold Casting Processes
  • 14.1 Introduction
  • 14.2 Sand Casting
  • 14.3 Cores and Core Making
  • 14.4 Additive and Advanced Manufacturing Applied to Casting
  • 14.5 Other Expendable-Mold Processes with Multiple-Use Patterns
  • 14.6 Expendable-Mold Processes Using Single-Use Patterns
  • 14.7 Shakeout, Cleaning, and Finishing
  • 14.8 Summary
  • Key Words
  • Review Questions
  • Problems
  • CASE STUDY Trailer Hitch Component
  • Note
  • CHAPTER 15: Multiple-Use-Mold Casting Processes
  • 15.1 Introduction
  • 15.2 Permanent-Mold Casting
  • 15.3 Die Casting
  • 15.4 Squeeze Casting and Semisolid Casting
  • 15.5 Centrifugal Casting
  • 15.6 Continuous Casting
  • 15.7 Melting
  • 15.8 Pouring Practice
  • 15.9 Cleaning, Finishing, Heat Treating, and Inspection
  • 15.10 Automation in Foundry Operations
  • 15.11 Process Selection
  • Key Words
  • Review Questions
  • Problems
  • CASE STUDY Baseplate for a Household Steam Iron
  • Notes
  • CHAPTER 16: Powder Metallurgy (Particulate Processing)
  • 16.1 Introduction
  • 16.2 The Basic Process
  • 16.3 Powder Manufacture
  • 16.4 Powder Testing and Evaluation
  • 16.5 Powder Mixing and Blending
  • 16.6 Compacting
  • 16.7 Sintering
  • 16.8 Advances in Sintering (Shorter Time, Higher Density, Stronger Products)
  • 16.9 Hot-Isostatic Pressing
  • 16.10 Other Techniques to Produce P/M Products
  • 16.11 Metal Injection Molding (MIM)
  • 16.12 Secondary Operations
  • 16.13 Properties of P/M Products
  • 16.14 Design of Powder Metallurgy Parts
  • 16.15 Powder Metallurgy Products
  • 16.16 Advantages and Disadvantages of Powder Metallurgy
  • 16.17 Process Summary
  • Key Words
  • Review Questions
  • Problems
  • Note
  • CHAPTER 17: Fundamentals of Metal Forming
  • 17.1 Introduction
  • 17.2 Forming Processes: Independent Variables
  • 17.3 Dependent Variables
  • 17.4 Independent–Dependent Relationships
  • 17.5 Process Modeling
  • 17.6 General Parameters
  • 17.7 Friction, Lubrication, and Wear Under Metal-Working Conditions
  • 17.8 Temperature Concerns
  • 17.9 Formability
  • Key Words
  • Review Questions
  • Problems
  • CASE STUDY Interior Tub of a Top-Loading Washing Machine
  • Note
  • CHAPTER 18: Bulk-Forming Processes
  • 18.1 Introduction
  • 18.2 Classification of Deformation Processes
  • 18.3 Bulk Deformation Processes
  • 18.4 Rolling
  • 18.5 Forging
  • 18.6 Extrusion
  • 18.7 Wire, Rod, and Tube Drawing
  • 18.8 Cold Forming, Cold Forging, and Impact Extrusion
  • 18.9 Piercing
  • 18.10 Other Squeezing Processes
  • 18.11 Surface Improvement by Deformation Processing
  • Key Words
  • Review Questions
  • Problems
  • CASE STUDY Automotive Engine Connecting Rod
  • Notes
  • CHAPTER 19: Sheet-Forming Processes
  • 19.1 Introduction
  • 19.2 Shearing Operations
  • 19.3 Bending
  • 19.4 Drawing and Stretching Processes
  • 19.5 Alternative Methods of Producing Sheet-Type Products
  • 19.6 Seamed Pipe Manufacture
  • 19.7 Presses
  • Key Words
  • Review Questions
  • Problems
  • CASE STUDY Automotive Body Panels
  • Notes
  • CHAPTER 20: Fabrication of Plastics, Ceramics, and Composites
  • 20.1 Introduction
  • 20.2 Fabrication of Plastics
  • 20.3 Processing of Rubber and Elastomers
  • 20.4 Processing of Ceramics
  • 20.5 Fabrication of Composite Materials
  • Key Words
  • Review Questions
  • Problems
  • CHAPTER 21: Fundamentals of Machining/Orthogonal Machining
  • 21.1 Introduction
  • 21.2 Fundamentals
  • 21.3 Forces and Power in Machining
  • 21.4 Orthogonal Machining (Two Forces)
  • 21.5 Chip Thickness Ratio, rc
  • 21.6 Mechanics of Machining (Statics)
  • 21.7 Shear Strain, γ, and Shear Front Angle, φ
  • 21.8 Mechanics of Machining (Dynamics) (Section courtesy of Dr. Elliot Stern)
  • Key Words
  • Review Questions
  • Problems
  • CASE STUDY Orthogonal Plate Machining Experiment at Auburn University
  • CHAPTER 22: Cutting Tool Materials
  • 22.1 Cutting Tool Materials
  • 22.2 Tool Geometry
  • 22.3 Tool-Coating Processes
  • 22.4 Tool Failure and Tool Life
  • 22.5 Taylor Tool Life
  • 22.6 Cutting Fluids
  • 22.7 Economics of Machining
  • Key Words
  • Review Questions
  • Problems
  • Note
  • CHAPTER 23: Turning and Boring Processes
  • 23.1 Introduction
  • 23.2 Fundamentals of Turning, Boring, and Facing Turning
  • 23.3 Lathe Design and Terminology
  • 23.4 Cutting Tools for Lathes
  • 23.5 Workholding in Lathes
  • Key Words
  • Review Questions
  • Problems
  • CASE STUDY  Estimating the Machining Time for Turning
  • CHAPTER 24: Milling
  • 24.1 Introduction
  • 24.2 Fundamentals of Milling Processes
  • 24.3 Milling Tools and Cutters
  • 24.4 Machines for Milling
  • Key Words
  • Review Questions
  • Problems
  • CASE STUDY HSS vs. Tungsten Carbide Milling
  • CHAPTER 25: Drilling and RelatedHole-Making Processes
  • 25.1 Introduction
  • 25.2 Fundamentals of the Drilling Process
  • 25.3 Types of Drills
  • 25.4 Tool Holders for Drills
  • 25.5 Workholding for Drilling
  • 25.6 Machine Tools for Drilling
  • 25.7 Cutting Fluids for Drilling
  • 25.8 Counterboring, Countersinking, and Spot Facing
  • 25.9 Reaming
  • Key Words
  • Review Questions
  • Problems
  • CASE STUDY Bolt-down Leg on a Casting
  • CHAPTER 26: CNC Processes and Adaptive Control: A(4) and A(5) Levels of Automation
  • 26.1 Introduction
  • 26.2 Basic Principles of Numerical Control
  • 26.3 CNC Part Programming
  • 26.4 Interpolation and Adaptive Control
  • 26.5 Machining Center Features and Trends
  • 26.6 Summary
  • Key Words
  • Review Questions
  • Problems
  • CHAPTER 27: Sawing, Broaching, Shaping, and Filing Machining Processes
  • 27.1 Introduction
  • 27.2 Introduction to Sawing
  • 27.3 Introduction to Broaching
  • 27.4 Fundamentals of Broaching
  • 27.5 Broaching Machines
  • 27.6 Introduction to Shaping and Planing
  • 27.7 Introduction to Filing
  • Key Words
  • Review Questions
  • Problems
  • CASE STUDY  Three Case Studies on Cost Estimating
  • CHAPTER 28: Abrasive Machining Processes
  • 28.1 Introduction
  • 28.2 Abrasives
  • 28.3 Grinding Wheel Structure and Grade
  • 28.4 Grinding Wheel Identification
  • 28.5 Grinding Machines
  • 28.6 Honing
  • 28.7 Superfinishing
  • 28.8 Free Abrasives
  • 28.9 Design Considerations in Grinding
  • Key Words
  • Review Questions
  • Problems
  • CASE STUDY Process Planning for the MfE
  • CHAPTER 29: Nano- and Micro-Manufacturing Processes
  • 29.1 Introduction
  • 29.2 Lithography
  • 29.3 Micromachining Processes
  • 29.4 Deposition Processes
  • 29.5 How ICs Are Made
  • 29.6 Nano- and Microscale Metrology
  • Key Words
  • Review Questions
  • Problems
  • CHAPTER 30: Nontraditional Manufacturing Processes
  • 30.1 Introduction
  • 30.2 Chemical Machining Processes
  • 30.3 Electrochemical Machining Processes
  • 30.4 Electrical Discharge Machining
  • Key Words
  • Review Questions
  • CHAPTER 31: Thread and Gear Manufacturing
  • 31.1 Introduction
  • 31.2 Thread Making
  • 31.3 Internal Thread Cutting–Tapping
  • 31.4 Thread Milling
  • 31.5 Thread Grinding
  • 31.6 Thread Rolling
  • 31.7 Gear Theory and Terminology
  • 31.8 Gear Types
  • 31.9 Gear Manufacturing
  • 31.10 Machining of Gears
  • 31.11 Gear Finishing
  • 31.12 Gear Inspection
  • Key Words
  • Review Questions
  • Problems
  • CASE STUDY Bevel Gear for a Riding Lawn Mower
  • CHAPTER 32: Surface Integrity and Finishing Processes
  • 32.1 Introduction
  • 32.2 Surface Integrity
  • 32.3 Abrasive Cleaning and Finishing
  • 32.4 Chemical Cleaning
  • 32.5 Coatings
  • 32.6 Vaporized Metal Coatings
  • 32.7 Clad Materials
  • 32.8 Textured Surfaces
  • 32.9 Coil-Coated Sheets
  • 32.10 Edge Finishing and Burr Removal
  • Key Words
  • Review Questions
  • Problems
  • CASE STUDY Dana Lynn’s Fatigue Lesson
  • CHAPTER 33: Additive Manufacturing Processes: “3-D Printing”
  • 33.1 Introduction
  • 33.2 History and General Categorizations
  • 33.3 Standard Classifications
  • 33.4 Technical Details: Digital to Physical Solid Objects
  • 33.5 General Details of Additive Manufacturing Systems
  • 33.6 Overview and Engineering Details of Some AM Systems
  • 33.7 Other Considerations
  • 33.8 Current Uses and Future Trends
  • 33.9 Pros, Cons, and Economic Considerations
  • Key Words
  • Review Questions
  • Problems
  • Notes
  • CHAPTER 34: Manufacturing Automation and Industrial Robots
  • 34.1 Introduction
  • 34.2 The A(4) Level of Automation
  • 34.3 A(5) Level of Automation Requires Evaluation
  • 34.4 Industrial Robotics
  • 34.5 Computer-Integrated Manufacturing (CIM)
  • 34.6 Computer-Aided Design
  • 34.7 Computer-Aided Manufacturing
  • 34.8 Summary
  • Key Words
  • Review Questions
  • Problems
  • CHAPTER 35: Fundamentals of Joining
  • 35.1 Introduction to Consolidation Processes
  • 35.2 Classification of Welding and Thermal Cutting Processes
  • 35.3 Some Common Concerns
  • 35.4 Types of Fusion Welds and Types of Joints
  • 35.5 Design Considerations
  • 35.6 Heat Effects
  • 35.7 Weldability or Joinability
  • 35.8 Summary
  • Key Words
  • Review Questions
  • Problems
  • Note
  • CHAPTER 36: Gas Flame and Arc Processes
  • 36.1 Oxyfuel-Gas Welding
  • 36.2 Oxygen Torch Cutting
  • 36.3 Flame Straightening
  • 36.4 Arc Welding
  • 36.5 Consumable-Electrode Arc Welding
  • 36.6 Nonconsumable Electrode Arc Welding
  • 36.7 Other Processes Involving Arcs
  • 36.8 Arc Cutting
  • 36.9 Metallurgical and Heat Effects in Thermal Cutting
  • 36.10 Welding Equipment
  • 36.11 Thermal Deburring
  • Key Words
  • Review Questions
  • Problems
  • CASE STUDY Bicycle Frame Construction and Repair
  • CHAPTER 37: Resistance and Solid-State Welding Processes
  • 37.1 Introduction
  • 37.2 Theory of Resistance Welding
  • 37.3 Resistance Welding Processes
  • 37.4 Advantages and Limitations of Resistance Welding
  • 37.5 Solid-State Welding Processes
  • Key Words
  • Review Questions
  • Problems
  • CASE STUDY Manufacture of an Automobile Muffler
  • CHAPTER 38: Other Welding Processes, Brazing, and Soldering
  • 38.1 Introduction
  • 38.2 Other Welding and Cutting Processes
  • 38.3 Surface Modification by Welding-Related Processes
  • 38.4 Brazing
  • 38.5 Soldering
  • Key Words
  • Review Questions
  • Problems
  • CASE STUDY Impeller of a Pharmaceutical Company Industrial Shredder/Disposal
  • Notes
  • CHAPTER 39: Adhesive Bonding, Mechanical Fastening, and Joining of Nonmetals
  • 39.1 Adhesive Bonding
  • 39.2 Mechanical Fastening
  • 39.3 Joining of Plastics
  • 39.4 Joining of Ceramics and Glass
  • 39.5 Joining of Composite
  • Key Words
  • Review Questions
  • Problems
  • CASE STUDY Golf Club Heads with Insert
  • Note
  • Index
  • End User License Agreement