Guiding engineering and technology students for over five decades, DeGarmo's Materials and Processes in Manufacturing provides a comprehensive introduction to manufacturing materials, systems, and processes. Coverage of materials focuses on properties and behavior, favoring a practical approach over complex mathematics; analytical equations and mathematical models are only presented when they strengthen comprehension and provide clarity. Material production processes are examined in the context of practical application to promote efficient understanding of basic principles, and broad coverage of manufacturing processes illustrates the mechanisms of each while exploring their respective advantages and limitations.
Aiming for both accessibility and completeness, this text offers introductory students a comprehensive guide to material behavior and selection, measurement and inspection, machining, fabrication, molding, fastening, and other important processes using plastics, ceramics, composites, and ferrous and nonferrous metals and alloys. This extensive overview of the field gives students a solid foundation for advanced study in any area of engineering, manufacturing, and technology.
Table of Contents
Preface iii
Acronyms xiii
1 Introduction to DeGarmo’s Materials and Processes in Manufacturing 1
1.1 Materials, Manufacturing, and the Standard of Living 1
1.2 Manufacturing and Production Systems 2
2 Properties of Materials 23
2.1 Introduction 23
2.2 Static Properties 24
2.3 Dynamic Properties 34
2.4 Temperature Effects (Both High and Low) 39
2.5 Machinability, Formability, and Weldability 42
2.6 Fracture Toughness and the Fracture Mechanics Approach 42
2.7 Physical Properties 43
2.8 Testing Standards and Testing Concerns 43
3 Nature of Materials 45
3.1 Structure - Property - Processing - Performance Relationships 45
3.2 The Structure of Atoms 45
3.3 Atomic Bonding 46
3.4 Secondary Bonds 47
3.5 Atom Arrangements in Materials 48
3.6 Crystal Structures 48
3.7 Development of a Grain Structure 49
3.8 Elastic Deformation 50
3.9 Plastic Deformation 50
3.10 Dislocation Theory of Slippage 52
3.11 Strain Hardening or Work Hardening 53
3.12 Plastic Deformation in Polycrystalline Material 53
3.13 Grain Shape and Anisotropic Properties 54
3.14 Fracture 54
3.15 Cold Working, Recrystallization, and Hot Working 54
3.16 Grain Growth 55
3.17 Alloys and Alloy Types 55
3.18 Atomic Structure and Electrical Properties 56
4 Equilibrium Phase Diagrams and the Iron-Carbon System 57
4.1 Introduction 57
4.2 Phases 57
4.3 Equilibrium Phase Diagrams 57
4.4 Iron-Carbon Equilibrium Diagram 63
4.5 Steels and the Simplified Iron-Carbon Diagram 64
4.6 Cast Irons 65
5 Heat Treatment 67
5.1 Introduction 67
5.2 Processing Heat Treatments 67
5.3 Heat Treatments Used to Increase Strength 69
5.4 Strengthening Heat Treatments for Nonferrous Metals 70
5.5 Strengthening Heat Treatments for Steel 72
5.6 Surface Hardening of Steel 83
5.7 Furnaces 84
5.8 Heat Treatment and Energy 86
6 Ferrous Metals and Alloys 87
6.1 Introduction to History-Dependent Materials 87
6.2 Ferrous Metals 87
6.3 Iron 88
6.4 Steel 88
6.5 Stainless Steels 98
6.6 Tool Steels 100
6.7 Cast Irons 102
6.8 Cast Steels 105
6.9 The Role of Processing on Cast Properties 105
7 Nonferrous Metals and Alloys 106
7.1 Introduction 106
7.2 Copper and Copper Alloys 106
7.3 Aluminum and Aluminum Alloys 111
7.4 Magnesium and Magnesium Alloys 115
7.5 Zinc and Zinc Alloys 118
7.6 Titanium and Titanium Alloys 119
7.7 Nickel-Based Alloys 120
7.8 Superalloys, Refractory Metals, and Other Materials Designed for High-Temperature Service 120
7.9 Lead and Tin and Their Alloys 123
7.10 Some Lesser-Known Metals and Alloys 123
7.11 Metallic Glasses 123
7.12 Graphite 123
7.13 Materials for Specific Applications 124
7.14 High Entropy Alloys 124
8 Nonmetallic Materials: Plastics, Elastomers, Ceramics, and Composites 125
8.1 Introduction 125
8.2 Plastics 125
8.3 Elastomers 135
8.4 Ceramics 137
8.5 Composite Materials 145
9 Material Selection 153
9.1 Introduction 153
9.2 Material Selection and Manufacturing Processes 155
9.3 The Design Process 155
9.4 Approaches to Material Selection 156
9.5 Additional Factors to Consider 158
9.6 Consideration of the Manufacturing Process 159
9.7 Ultimate Objective 159
9.8 Materials Substitution 161
9.9 Effect of Product Liability on Materials Selection 161
9.10 Aids to Material Selection 162
10 Measurement and Inspection 163
10.1 Introduction 163
10.2 Standards of Measurement 163
10.3 Allowance and Tolerance 166
10.4 Inspection Methods for Measurement 171
10.5 Measuring Instruments 172
10.6 Vision Systems 180
10.7 Coordinate Measuring Machines 180
10.8 Angle-Measuring Instruments 181
10.9 Gages for Attributes Measuring 182
11 Nondestructive Examination (NDE) / Nondestructive Testing (NDT) 186
11.1 Destructive vs. Nondestructive Testing 186
11.2 Visual Inspection 187
11.3 Liquid Penetrant Inspection 188
11.4 Magnetic Particle Inspection 189
11.5 Ultrasonic Inspection 190
11.6 Radiography 191
11.7 Eddy-Current Testing 192
11.8 Acoustic Emission Monitoring 194
11.9 Other Methods of Nondestructive Testing and Inspection 195
11.10 Dormant vs. Critical Flaws 196
11.11 Current and Future Trends 196
12 Process Capability and Quality Control 197
12.1 Introduction 197
12.2 Determining Process Capability 198
12.3 Introduction to Statistical Quality Control 204
12.4 Sampling Errors 207
12.5 Gage Capability 208
12.6 Just in Time/Total Quality Control 209
12.7 Six Sigma 217
12.8 Summary 220
13 Fundamentals of Casting 221
13.1 Introduction to Materials Processing 221
13.2 Introduction to Casting 222
13.3 Casting Terminology 223
13.4 The Solidification Process 223
13.5 Patterns 231
13.6 Design Considerations in Castings 232
13.7 The Casting Industry 234
14 Expendable-Mold Casting Processes 236
14.1 Introduction 236
14.2 Sand Casting 236
14.3 Cores and Core Making 249
14.4 Other Expendable-Mold Processes with Multiple- Use Patterns 252
14.5 Expendable-Mold Processes Using Single-Use Patterns 253
14.6 Shakeout, Cleaning, and Finishing 259
14.7 Summary 259
15 Multiple-Use-Mold Casting Processes 260
15.1 Introduction 260
15.2 Permanent-Mold Casting 260
15.3 Die Casting 263
15.4 Squeeze Casting and Semisolid Casting 266
15.5 Centrifugal Casting 267
15.6 Continuous Casting 269
15.7 Melting 269
15.8 Pouring Practice 271
15.9 Cleaning, Finishing, Heat Treating, and Inspection 272
15.10 Automation in Foundry Operations 273
15.11 Process Selection 273
16 Powder Metallurgy (Particulate Processing) 275
16.1 Introduction 275
16.2 The Basic Process 275
16.3 Powder Manufacture 276
16.4 Powder Testing and Evaluation 277
16.5 Powder Mixing and Blending 277
16.6 Compacting 278
16.7 Sintering 281
16.8 Advances in Sintering (Shorter Time, Higher Density, Stronger Products) 282
16.9 Hot-Isostatic Pressing 282
16.10 Other Techniques to Produce High-Density P/M Products 283
16.11 Metal Injection Molding (MIM) 284
16.12 Secondary Operations 285
16.13 Properties of P/M Products 287
16.14 Design of Powder Metallurgy Parts 288
16.15 Powder Metallurgy Products 289
16.16 Advantages and Disadvantages of Powder Metallurgy 290
16.17 Process Summary 291
17 Fundamentals of Metal Forming 292
17.1 Introduction 292
17.2 Forming Processes: Independent Variables 292
17.3 Dependent Variables 293
17.4 Independent-Dependent Relationships 294
17.5 Process Modeling 295
17.6 General Parameters 295
17.7 Friction, Lubrication, and Wear under Metalworking Conditions 296
17.8 Temperature Concerns 297
17.9 Formability 303
18 Bulk-Forming Processes 304
18.1 Introduction 304
18.2 Classification of Deformation Processes 304
18.3 Bulk Deformation Processes 304
18.4 Rolling 305
18.5 Forging 309
18.6 Extrusion 318
18.7 Wire, Rod, and Tube Drawing 322
18.8 Cold Forming, Cold Forging, and Impact Extrusion 324
18.9 Piercing 327
18.10 Other Squeezing Processes 328
18.11 Surface Improvement by Deformation Processing 330
19 Sheet-Forming Processes 331
19.1 Introduction 331
19.2 Shearing Operations 331
19.3 Bending 337
19.4 Drawing and Stretching Processes 343
19.5 Alternative Methods of Producing Sheet-Type Products 353
19.6 Seamed Pipe Manufacture 354
19.7 Presses 354
20 Fabrication of Plastics, Ceramics, and Composites 359
20.1 Introduction 359
20.2 Fabrication of Plastics 359
20.3 Processing of Rubber and Elastomers 369
20.4 Processing of Ceramics 369
20.5 Fabrication of Composite Materials 372
21 Fundamentals of Machining/ Orthogonal Machining 381
21.1 Introduction 381
21.2 Fundamentals 381
21.3 Forces and Power in Machining 386
21.4 Orthogonal Machining (Two Forces) 390
21.5 Chip Thickness Ratio, rc 394
21.6 Mechanics of Machining (Statics) 395
21.7 Shear Strain, γ, and Shear Front Angle, ϕ 397
21.8 Mechanics of Machining (Dynamics) (Section courtsey of Dr. Elliot Stern) 399
22 Cutting Tool Materials 405
22.1 Cutting Tool Materials 408
22.2 Tool Geometry 417
22.3 Tool-Coating Processes 419
22.4 Tool Failure and Tool Life 420
22.5 Taylor Tool Life 421
22.6 Cutting Fluids 425
22.7 Economics of Machining 426
23 Turning and Boring Processes 428
23.1 Introduction 428
23.2 Fundamentals of Turning, Boring, and Facing Turning 430
23.3 Lathe Design and Terminology 434
23.4 Cutting Tools for Lathes 438
23.5 Workholding in Lathes 442
24 Milling 447
24.1 Introduction 447
24.2 Fundamentals of Milling Processes 447
24.3 Milling Tools and Cutters 453
24.4 Machines for Milling 457
25 Drilling and Related Hole-Making Processes 462
25.1 Introduction 462
25.2 Fundamentals of the Drilling Process 463
25.3 Types of Drills 464
25.4 Tool Holders for Drills 472
25.5 Workholding for Drilling 474
25.6 Machine Tools for Drilling 475
25.7 Cutting Fluids for Drilling 478
25.8 Counterboring, Countersinking, and Spot Facing 479
25.9 Reaming 480
26 CNC Processes and Adaptive Control: A(4) and A(5) Levels of Automation 482
26.1 Introduction 482
26.2 Basic Principles of Numerical Control 482
26.3 CNC Part Programming 488
26.4 Interpolation and Adaptive Control 494
26.5 Machining Center Features and Trends 497
26.6 Summary 501
27 Sawing, Broaching, Shaping, and Filing Machining Processes 502
27.1 Introduction 502
27.2 Introduction to Sawing 502
27.3 Introduction to Broaching 510
27.4 Fundamentals of Broaching 512
27.5 Broaching Machines 516
27.6 Introduction to Shaping and Planing 516
27.7 Introduction to Filing 520
28 Abrasive Machining Processes 523
28.1 Introduction 523
28.2 Abrasives 524
28.3 Grinding Wheel Structure and Grade 528
28.4 Grinding Wheel Identification 531
28.5 Grinding Machines 534
28.6 Honing 540
28.7 Superfinishing 542
28.8 Free Abrasives 543
28.9 Design Considerations in Grinding 547
29 Nano and Micro-Manufacturing Processes 548
29.1 Introduction 548
29.2 Lithography 551
29.3 Micromachining Processes 554
29.4 Deposition Processes 556
29.5 How ICs Are Made 562
29.6 Nano- and Micro-Scale Metrology 568
30 Nontraditional Manufacturing Processes 570
30.1 Introduction 570
30.2 Chemical Machining Processes 572
30.3 Electrochemical Machining Processes 576
30.4 Electrical Discharge Machining 581
31 Thread and Gear Manufacturing 589
31.1 Introduction 589
31.2 Thread Making 592
31.3 Internal Thread Cutting-Tapping 595
31.4 Thread Milling 597
31.5 Thread Grinding 599
31.6 Thread Rolling 599
31.7 Gear Theory and Terminology 601
31.8 Gear Types 603
31.9 Gear Manufacturing 604
31.10 Machining of Gears 605
31.12 Gear Finishing 610
31.13 Gear Inspection 611
32 Surface Integrity and Finishing Processes 613
32.1 Introduction 613
32.2 Surface Integrity 613
32.3 Abrasive Cleaning and Finishing 620
32.4 Chemical Cleaning 624
32.5 Coatings 626
32.6 Vaporized Metal Coatings 633
32.7 Clad Materials 633
32.8 Textured Surfaces 633
32.9 Coil-Coated Sheets 633
32.10 Edge Finishing and Burr Removal 634
33 Additive Processes - Including 3-D Printing 637
33.1 Introduction 637
33.2 Layerwise Manufacturing 638
33.3 Liquid-Based Processes 641
33.4 Powder-Based Processes 643
33.5 Deposition-Based Processes 647
33.6 Uses and Applications 649
33.7 Pros, Cons, and Current and Future Trends 652
33.8 Economic Considerations 655
34 Manufacturing Automation and Industrial Robots 656
34.1 Introduction 656
34.2 The A(4) Level of Automation 660
34.3 A(5) Level of Automation Requires Evaluation 666
34.4 Industrial Robotics 669
34.5 Computer-Integrated Manufacturing (CIM) 675
34.6 Computer-Aided Design 677
34.7 Computer-Aided Manufacturing 678
34.8 Summary 679
35 Fundamentals of Joining 680
35.1 Introduction to Consolidation Processes 680
35.2 Classification of Welding and Thermal Cutting Processes 681
35.3 Some Common Concerns 681
35.4 Types of Fusion Welds and Types of Joints 681
35.5 Design Considerations 682
35.6 Heat Effects 684
35.7 Weldability or Joinability 688
35.8 Summary 689
36 Gas Flame and Arc Processes 690
36.1 Oxyfuel-Gas Welding 690
36.2 Oxygen Torch Cutting 693
36.3 Flame Straightening 694
36.4 Arc Welding 695
36.5 Consumable-Electrode Arc Welding 696
36.6 Nonconsumable Electrode Arc Welding 702
36.7 Other Processes Involving Arcs 706
36.8 Arc Cutting 707
36.9 Metallurgical and Heat Effects in Thermal Cutting 709
36.10 Welding Equipment 710
36.11 Thermal Deburring 711
37 Resistance and Solid-State Welding Processes 712
37.1 Introduction 712
37.2 Theory of Resistance Welding 712
37.3 Resistance Welding Processes 714
37.4 Advantages and Limitations of Resistance Welding 717
37.5 Solid-State Welding Processes 718
38 Other Welding Processes, Brazing, and Soldering 726
38.1 Introduction 726
38.2 Other Welding and Cutting Processes 726
38.3 Surface Modification by Welding-Related Processes 732
38.4 Brazing 735
38.5 Soldering 742
39 Adhesive Bonding, Mechanical Fastening, and Joining of Nonmetals 746
39.1 Adhesive Bonding 746
39.2 Mechanical Fastening 752
39.3 Joining of Plastics 755
39.4 Joining of Ceramics and Glass 758
39.5 Joining of Composites 758
40 JIG and Fixture Design W 1
41 The Enterprise (Production System) W 20
42 Lean Engineering W 35
43 Mixed-Model Final Assembly W 65
Index I- 1
