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A comprehensive text on the science, engineering, and technology of manufacturing

In  Manufacturing Engineering and Technology , 8th Edition, the authors continue their efforts to present a comprehensive, balanced, and, most importantly, an up-to-date coverage of the science, engineering, and technology of manufacturing. It places an emphasis on the interdisciplinary nature of every manufacturing activity, from complex interactions between materials, design, process, and manufacturing process and operations.

The text is designed to help students learn not only the science and engineering that drives manufacturing, but to understand and appreciate manufacturing’s important role in our modern, global economy. With more than 120 examples and case studies, the text presents students with a breadth of challenges while providing them the tools and encouragement to explore solutions to those challenges.

With the 8th Edition,  Manufacturing Engineering and Technology  is now available as an eText for a convenient, simple-to-use mobile reading experience for the needs and habits of today’s students. The new edition is thoroughly updated with numerous new topics and illustrations relevant to all aspects of manufacturing and includes a completely revised chapter covering the rapid advances in additive manufacturing.

This title is also available digitally as a standalone Pearson eText. This option gives students affordable access to learning materials, so they come to class ready to succeed.

Serope Kalpakjian is professor emeritus of Mechanical and Materials Engineering, the Illinois Institute of Technology. He is the author of Mechanical Processing of Materials and co-author of Lubricants and Lubrication in Metalworking Operations (with E.S. Nachtman). The first editions of his textbooks Manufacturing Processes for Engineering Materials and Manufacturing Engineering and Technology have received the M. Eugene Merchant Manufacturing Textbook Award. He has conducted research in various areas of manufacturing, is the author of numerous technical papers and articles in handbooks and encyclopedias, and has edited a number of conference proceedings. He also has been editor and co-editor of several technical journals and has served on various editorial boards, including the Encyclopedia Americana. 

Among various awards, Professor Kalpakjian has received the Forging Industry Educational and Research Foundation Best Paper Award, the Excellence in Teaching Award from lIT, the ASME Centennial Medallion, the International Education Award from SME, A Person of the Millennium Award from lIT, the Albert Easton White Outstanding Teacher Award from ASM International, and the 2016 SME Gold Medal Award. The Outstanding Young Manufacturing Engineer Award of SME, for 2001, was named after him. Professor Kalpakjian is a Life Fellow ASME, Fellow SME, Fellow and Life Member ASM International, Fellow Emeritus International Academy for Production Engineering (CIRP), and is a founding member and past president of NAMRI. He is a graduate of Robert College (High Honor, Istanbul), Harvard University, and the Massachusetts Institute of Technology. 

Steven R. Schmid is professor of Aerospace and Mechanical Engineering, the University of Notre Dame, where he teaches and conducts research in the general areas of manufacturing, machine design, and tribology. From 2016 to 2018, he served as a Program Director of the Advanced Manufacturing Program at the National Science Foundation. He received his B.S. degree from Illinois Institute of Technology (with Honors) and Master’s and Ph.D. degrees from Northwestern University, all in mechanical engineering. He has received numerous awards, including the John T. Parsons Award from SME, the Newkirk Award from ASME, the Kaneb Center Teaching Award (three times), and the Ruth and Joel Spira Award for Excellence in Teaching. 

Professor Schmid served as President of the North American Manufacturing Research Institution (NAMRI, 2015-2016) and was appointed the first Academic Fellow at the Advanced Manufacturing National Program Office, U.S. Department of Commerce, where he helped design the Manufacturing USA program. Dr. Schmid is the author of over 140 technical papers, and has co-authored Fundamentals of Machine Elements, Fundamentals of Fluid Film Lubrication, it Manufacturing Processes for Engineering Materials, and Manufacturing Engineering and Technology. He is a Fellow of the American Society of Mechanical Engineers and the Society of Manufacturing Engineers. He was elected to the Board of the Society of Manufacturing Engineers in 2018.

Preface xxiii

About the Authors xxvi

General Introduction

I.1 What is Manufacturing?

I.2 Product Design and Concurrent Engineering

I.3 Design for Manufacture, Assembly, Disassembly, and Service

I.4 Environmentally Conscious Design, Sustainable Manufacturing, and Product Life Cycle

I.5 Selection of Materials

I.6 Selection of Manufacturing Processes

I.7 Computer-integrated Manufacturing

I.8 Quality Assurance and Total Quality Management

I.9 Lean Production and Agile Manufacturing

I.10 Manufacturing Costs and Global Competition

I.11 Trends in Manufacturing

PART I: FUNDAMENTALS OF MATERIALS: BEHAVIOR AND MANUFACTURING PROPERTIES

1. The Structure of Metals

1.1 Introduction
1.2 Types of Atomic Bonds
1.3 The Crystal Structure of Metals
1.4 Deformation and Strength of Single Crystals
1.5 Grains and Grain Boundaries
1.6 Plastic Deformation of Polycrystalline Metals
1.7 Recovery, Recrystallization, and Grain Growth

1.8 Cold, Warm, and Hot Working

2. Mechanical Behavior, Testing, and Manufacturing Properties of Materials

2.1 Introduction

2.2 Tension

2.3 Compression

2.4 Torsion

2.5 Bending (Flexure)

2.6 Hardness

2.7 Fatigue

2.8 Creep

2.9 Impact

2.10 Failure and Fracture of Materials

2.11 Residual Stresses

2.12 Work, Heat, and Temperature

3. Physical Properties of Materials

3.1 Introduction

3.2 Density

3.3 Melting Point

3.4 Specific Heat

3.5 Thermal Conductivity

3.6 Thermal Expansion

3.7 Electrical, Magnetic, and Optical Properties

3.8 Corrosion Resistance

4. Metal Alloys: Their Structure and Strengthening by Heat Treatment

4.1 Introduction

4.2 Structure of Alloys

4.3 Phase Diagrams

4.4 The Iron-Carbon System

4.5 The Iron—Iron-carbide Phase Diagram and the Development of Microstructures in Steels

4.6 Cast Irons

4.7 Heat Treatment of Ferrous Alloys

4.8 Hardenability of Ferrous Alloys

4.9 Heat Treatment of Nonferrous Alloys and Stainless Steels

4.10 Case Hardening

4.11 Annealing

4.12 Heat-treating Furnaces and Equipment

4.13 Design Considerations for Heat Treating

5. Ferrous Metals and Alloys: Production, General Properties, and Applications

5.1 Introduction

5.2 Production of Iron and Steel

5.3 Casting of Ingots

5.4 Continuous Casting

5.5 Carbon and Alloy Steels

5.6 Stainless Steels

5.7 Tool and Die Steels

6. Nonferrous Metals and Alloys: Production, General Properties, and Applications

6.1 Introduction

6.2 Aluminum and Aluminum Alloys

6.3 Magnesium and Magnesium Alloys

6.4 Copper and Copper Alloys

6.5 Nickel and Nickel Alloys

6.6 Superalloys

6.7 Titanium and Titanium Alloys

6.8 Refractory Metals and Alloys

6.9 Beryllium

6.10 Zirconium

6.11 Lithium

6.12 Low-melting Alloys

6.13 Precious Metals

6.14 Shape-memory Alloys (Smart Materials)

6.15 Amorphous Alloys (Metallic Glasses)

6.16 Metal Foams and Metamaterials

6.17 Rare Earth Metals

7. Polymers: Structure, General Properties, and Applications

7.1 Introduction

7.2 The Structure of Polymers

7.3 Thermoplastics

7.4 Thermosetting Plastics

7.5 Additives in Plastics

7.6 General Properties and Applications of Thermoplastics

7.7 General Properties and Applications of Thermosetting Plastics

7.8 Biodegradable Plastics

7.9 Elastomers (Rubbers)

8. Ceramics, Glass, Graphite, Diamond, and Nanomaterials: Structure, General Properties, and Applications

8.1 Introduction

8.2 The Structure of Ceramics

8.3 General Properties and Applications of Ceramics

8.4 Glasses

8.5 Glass Ceramics

8.6 Graphite

8.7 Diamond

8.8 Nanomaterials

9. Composite Materials: Structure, General Properties, and Applications

9.1 Introduction

9.2 The Structure of Reinforced Plastics

9.3 Properties of Reinforced Plastics

9.4 Applications of Reinforced Plastics

9.5 Metal-matrix Composites

9.6 Ceramic-matrix Composites

9.7 Other Composites

PART II: METAL-CASTING PROCESSES AND EQUIPMENT

10. Fundamentals of Metal Casting

10.1 Introduction

10.2 Solidification of Metals

10.3 Fluid Flow

10.4 Fluidity of Molten Metal

10.5 Heat Transfer

10.6 Defects

11. Metal-casting Processes and Equipment

11.1 Introduction

11.2 Expendable-mold, Permanent-pattern Casting Processes

11.3 Expendable-mold, Expendable-pattern Casting Processes

11.4 Permanent-mold Casting Processes

11.5 Casting Techniques for Single-crystal Components

11.6 Rapid Solidification

11.7 Inspection of Castings

11.8 Melting Practice and Furnaces

11.9 Foundries and Foundry Automation

12. Metal Casting: Design, Materials, and Economics

12.1 Introduction

12.2 Design Considerations in Casting

12.3 Casting Alloys

12.4 Economics of Casting

PART III: FORMING AND SHAPING PROCESSES AND EQUIPMENT

13. Metal-rolling Processes and Equipment

13.1 Introduction

13.2 The Flat-rolling Process

13.3 Flat-rolling Practice

13.4 Rolling Mills

13.5 Various Rolling Processes and Mills

14. Metal-forging Processes and Equipment

14.1 Introduction

14.2 Open-die Forging

14.3 Impression-die and Closed-die Forging

14.4 Various Forging Operations

14.5 Forgeability of Metals; Forging Defects

14.6 Die Design, Die Materials, and Lubrication

14.7 Die-manufacturing Methods and Die Failure

14.8 Forging Machines

14.9 Economics of Forging

15. Metal Extrusion and Drawing Processes and Equipment

15.1 Introduction

15.2 The Extrusion Process

15.3 Hot Extrusion

15.4 Cold Extrusion

15.5 Extrusion Defects

15.6 Design Considerations

15.7 Extrusion Equipment

15.8 The Drawing Process

15.9 Drawing Practice

15.10 Drawing Defects and Residual Stresses

15.11 Drawing Equipment

16. Sheet-Metal Forming Processes and Equipment

16.1 Introduction

16.2 Shearing

16.3 Sheet-metal Characteristics and Formability

16.4 Formability Tests for Sheet Metals

16.5 Bending Sheets, Plates, and Tubes

16.6 Miscellaneous Bending and Related Forming Operations

16.7 Deep Drawing

16.8 Rubber Forming and Hydroforming

16.9 Spinning

16.10 Superplastic Forming

16.11 Hot Stamping

16.12 Specialized Forming Processes

16.13 Manufacturing of Metal Honeycomb Structures

16.14 Design Considerations in Sheet-metal Forming

16.15 Equipment for Sheet-metal Forming

16.16 Economics of Sheet-forming Operations

17. Powder Metal Processes and Equipment

17.1 Introduction

17.2 Production of Metal Powders

17.3 Compaction of Metal Powders

17.4 Sintering

17.5 Secondary and Finishing Operations

17.6 Design Considerations

17.7 Economics of Powder Metallurgy

18. Ceramics, Glasses, and Superconductors: Processing and Equipment

18.1 Introduction

18.2 Shaping Ceramics

18.3 Forming and Shaping of Glass

18.4 Techniques for Strengthening and Annealing Glass

18.5 Design Considerations for Ceramics and Glasses

18.6 Processing of Superconductors

19. Plastics and Composite Materials: Forming and Shaping

19.1 Introduction

19.2 Extrusion

19.3 Injection Molding

19.4 Blow Molding

19.5 Rotational Molding

19.6 Thermoforming

19.7 Compression Molding

19.8 Transfer Molding

19.9 Casting

19.10 Foam Molding

19.11 Cold Forming and Solid-phase Forming

19.12 Processing Elastomers

19.13 Processing Polymer-matrix Composites

19.14 Processing Metal-matrix and Ceramic-matrix Composites

19.15 Design Considerations

19.16 Economics of Processing Plastics and Composite Materials

20. Additive Manufacturing

20.1 Introduction

20.2 Additive Manufacturing Methodology

20.3 Extrusion-based Processes

20.4 Photopolymerization

20.5 Material Jetting

20.6 Powder Bed Processes

20.7 Laminated-object Manufacturing

20.8 Miscellaneous Processes

20.9 Emerging AM Applications

20.10 Direct Manufacturing and Rapid Tooling

20.11 Design for Additive Manufacturing

20.12 Additive Manufacturing Economics

PART IV: MACHINING PROCESSES AND MACHINE TOOLS

21. Fundamentals of Machining

21.1 Introduction

21.2 Mechanics of Cutting

21.3 Cutting Forces and Power

21.4 Temperatures in Cutting

21.5 Tool Life: Wear and Failure

21.6 Surface Finish and Integrity

21.7 Machinability

22. Cutting-Tool Materials and Cutting Fluids

22.1 Introduction

22.2 High-speed Steels

22.3 Cast-cobalt Alloys

22.4 Carbides

22.5 Coated Tools

22.6 Alumina-based Ceramics

22.7 Cubic Boron Nitride

22.8 Silicon-Nitride-based Ceramics

22.9 Diamond

22.10 Whisker-reinforced Materials and Nanomaterials

22.11 Tool Costs and Reconditioning of Tools

22.12 Cutting Fluids

23. Machining Processes: Turning and Hole Making

23.1 Introduction

23.2 The Turning Process

23.3 Lathes and Lathe Operations

23.4 Boring and Boring Machines

23.5 Drilling, Drills, and Drilling Machines

23.6 Reaming and Reamers

23.7 Tapping and Taps

24. Machining Processes: Milling, Broaching, Sawing, Filing, and Gear Manufacturing

24.1 Introduction

24.2 Milling and Milling Machines

24.3 Planing and Shaping

24.4 Broaching and Broaching Machines

24.5 Sawing

24.6 Filing

24.7 Gear Manufacturing by Machining

25. Machining Centers, Machine-tool Structures, and Machining Economics

25.1 Introduction

25.2 Machining Centers

25.3 Machine-tool Structures

25.4 Vibration and Chatter in Machining Operations

25.5 High-speed Machining

25.6 Hard Machining

25.7 Ultraprecision Machining

25.8 Machining Economics

26. Abrasive Machining and Finishing Operations

26.1 Introduction

26.2 Abrasives and Bonded Abrasives

26.3 The Grinding Process

26.4 Grinding Operations and Machines

26.5 Design Considerations for Grinding

26.6 Ultrasonic Machining

26.7 Finishing Operations

26.8 Deburring Operations

26.9 Economics of Abrasive Machining and Finishing Operations

27. Advanced Machining Processes

27.1 Introduction

27.2 Chemical Machining

27.3 Electrochemical Machining

27.4 Electrochemical Grinding

27.5 Electrical-discharge Machining

27.6 Laser-beam Machining

27.7 Electron-beam Machining

27.8 Water-jet Machining

27.9 Abrasive-jet Machining

27.10 Hybrid Machining Systems

27.11 Economics of Advanced Machining Processes

PART V: MICROMANUFACTURING AND FABRICATION OF MICROELECTRONIC DEVICES

28. Fabrication of Microelectronic Devices

28.1 Introduction

28.2 Clean Rooms

28.3 Semiconductors and Silicon

28.4 Crystal Growing and Wafer Preparation

28.5 Film Deposition

28.6 Oxidation

28.7 Lithography

28.8 Etching

28.9 Diffusion and Ion Implantation

28.10 Metallization and Testing

28.11 Wire Bonding and Packaging

28.12 Yield and Reliability

28.13 Printed Circuit Boards

28.14 Roll-to-Roll Printing of Flexible Electronics

28.15 Flexible Hybrid Electronics

29. Fabrication of Microelectromechanical Devices and Systems and Nanoscale Manufacturing

29.1 Introduction

29.2 Micromachining of MEMS Devices

29.3 Electroforming-based Processes

29.4 Solid Free-form Fabrication of Devices

29.5 Mesoscale Manufacturing

29.6 Nanoscale Manufacturing

PART VI: JOINING PROCESSES AND EQUIPMENT

30. Fusion Welding Processes

30.1 Introduction

30.2 Oxyfuel–Gas Welding

30.3 Arc-welding Processes: Nonconsumable Electrode

30.4 Arc-welding Processes: Consumable Electrode

30.5 Electrodes for Arc Welding

30.6 Electron-beam Welding

30.7 Laser-beam Welding

30.8 Cutting

30.9 The Weld Joint, Quality, and Testing

30.10 Joint Design and Process Selection

31. Solid-State Welding Processes

31.1 Introduction

31.2 Cold Welding and Roll Bonding

31.3 Ultrasonic Welding

31.4 Friction Welding

31.5 Resistance Welding

31.6 Explosion Welding

31.7 Diffusion Bonding

31.8 Economics of Welding Operations

32. Brazing, Soldering, Adhesive-bonding, and Mechanical Fastening Processes

32.1 Introduction

32.2 Brazing

32.3 Soldering

32.4 Adhesive Bonding

32.5 Mechanical Fastening

32.6 Joining Plastics, Ceramics, and Glasses

32.7 Economics of Joining Operations

PART VII: SURFACE TECHNOLOGY

33. Surface Roughness and Measurement; Friction, Wear, and Lubrication

33.1 Introduction

33.2 Surface Structure and Integrity

33.3 Surface Texture and Roughness

33.4 Friction

33.5 Wear

33.6 Lubrication

33.7 Metalworking Fluids and Their Selection

34. Surface Treatments, Coatings, and Cleaning

34.1 Introduction

34.2 Mechanical Surface Treatments

34.3 Mechanical Plating and Cladding

34.4 Case Hardening and Hard Facing

34.5 Thermal Spraying

34.6 Vapor Deposition

34.7 Ion Implantation and Diffusion Coating

34.8 Laser Treatments

34.9 Electroplating, Electroless Plating, and Electroforming

34.10 Conversion Coatings

34.11 Hot Dipping

34.12 Porcelain Enameling; Ceramic and Organic Coatings

34.13 Diamond Coating and Diamondlike Carbon

34.14 Surface Texturing

34.15 Painting

34.16 Cleaning of Surfaces

PART VIII: ENGINEERING METROLOGY, INSTRUMENTATION, AND QUALITY ASSURANCE

35. Surface Treatments, Coatings, and Cleaning

35.1 Introduction

35.2 Measurement Standards

35.3 Geometric Features of Parts: Analog and Digital Measurements

35.4 Traditional Measuring Methods and Instruments

35.5 Modern Measuring Instruments and Machines

35.6 Automated Measurement

35.7 General Characteristics and Selection of Measuring Instruments

35.8 Geometric Dimensioning and Tolerancing

36. Quality Assurance, Testing, and Inspection

36.1 Introduction

36.2 Product Quality

36.3 Quality Assurance

36.4 Total Quality Management

36.5 Taguchi Methods

36.6 The ISO and QS Standards

36.7 Statistical Methods of Quality Control

36.8 Statistical Process Control

36.9 Reliability of Products and Processes

36.10 Nondestructive Testing

36.11 Destructive Testing

36.12 Automated Inspection

PART IX: MANUFACTURING IN A COMPETITIVE ENVIRONMENT

37. Automation of Manufacturing Processes and Operations

37.1 Introduction

37.2 Automation

37.3 Numerical Control

37.4 Adaptive Control

37.5 Material Handling and Movement

37.6 Industrial Robots

37.7 Sensor Technology

37.8 Flexible Fixturing

37.9 Assembly Systems

37.10 Design Considerations for Fixturing, Assembly, Disassembly, and Servicing

37.11 Economic Considerations

38. Computer-aided Manufacturing

38.1 Introduction

38.2 Manufacturing Systems

38.3 Computer-integrated Manufacturing

38.4 Computer-aided Design and Engineering

38.5 Computer-aided Manufacturing

38.6 Computer-aided Process Planning

38.7 Computer Simulation of Manufacturing Processes and Systems

38.8 Group Technology

39. Computer-integrated Manufacturing Systems

39.1 Introduction

39.2 Cellular Manufacturing

39.3 Flexible Manufacturing Systems

39.4 Mass Customization

39.5 Holonic Manufacturing

39.6 Just-in-time Production

39.7 Lean Manufacturing

39.8 Communications Networks in Manufacturing

39.9 Artificial Intelligence and Machine Learning

39.10 Economic Considerations

40. Product Design and Manufacturing in a Competitive Environment

40.1 Introduction

40.2 Product Design

40.3 Product Quality

40.4 Life-cycle Assessment and Sustainable Manufacturing

40.5 Energy Consumption in Manufacturing

40.6 Material Selection for Products

40.7 Material Substitution

40.8 Manufacturing Process Capabilities

40.9 Process Selection

40.10 Manufacturing Costs and Cost Reduction