Manufacturing Engineering and Technology

1205 Pages·2009·35.619 MB·English

by  Serope Kalpakjian, Steven R. Schmid

A01_KALP1681_06_SE_FM.QXD 2/26/09 11:01 AM Page i
Manufacturing
Engineering
and Technology
SIXTH
EDITION
Serope Kalpakjian
Illinois Institute of Technology
Steven R. Schmid
The University of Notre Dame
PrenticeHall
NewYork Boston SanFrancisco
London Toronto Sydney Tokyo Singapore Madrid
MexicoCity Munich Paris CapeTown HongKong Montreal
A01_KALP1681_06_SE_FM.QXD 3/2/09 10:29 PM Page ii
LibraryofCongressCataloging-in-PublicationDataonFile
VicePresidentandEditorialDirector,ECS:MarciaJ.Horton
SeniorEditor:HollyStark
EditorialAssistant:WilliamOpaluch
DirectorofTeam-BasedProjectManagement:VinceO’Brien
SeniorManagingEditor:ScottDisanno
MarketingManager:TimGalligan
MarketingAssistant:MackPatterson
ProductionManager:ClareRomeo
ArtDirector:KennyBeck
CoverDesigner:KennyBeck
Manager,Rights&Permissions:ZinaArabia
Manager,VisualResearch:BethBrenzel
Manager,CoverVisualResearch&Permissions:DebbieLatronica
PhotoResearcher:MartaSamsel
CoverImages:BMWManufacturing—BMWofNorthAmerica,LLC;LaserCutting—MaximilianStockLtd./PhotoResearchers,Inc.;
Boeing787—BoeingCommercialAirplaneGroup;MetallicAbstract—RobynMackenzie/Shutterstock
Copyright©2010,2006,2001byPearsonEducation,Inc.
PearsonPrenticeHall
UpperSaddleRiver,NewJersey,07458
Allrightsreserved.PrintedintheUnitedStatesofAmerica.ThispublicationisprotectedbyCopyrightandpermissionshouldbeobtainedfrom
thepublisherpriortoanyprohibitedreproduction,storageinaretrievalsystem,ortransmissioninanyformorbyanymeans,electronic,
mechanical,photocopying,recording,orlikewise.Forinformationregardingpermission(s),writeto:RightsandPermissionsDepartment.
PearsonEducationLTD.
PearsonEducationAustraliaPTY,Limited
PearsonEducationSingapore,Pte.Ltd.
PearsonEducationNorthAsiaLtd.
PearsonEducation,Canada,Ltd.
PearsonEducacióndeMexico,S.A.deC.V.
PearsonEducation–Japan
PearsonEducationMalaysia,Pte.Ltd.
10 9 8 7 6 5 4 3 2 1
ISBN-13: 978-0-13-608168-5
ISBN-10: 0-13-608168-1
A01_KALP1681_06_SE_FM.QXD 2/19/09 2:59 PM Page iii
To
John A. Schey
esteemed colleague
and
dear friend
A01_KALP1681_06_SE_FM.QXD 2/19/09 2:59 PM Page iv
A01_KALP1681_06_SE_FM.QXD 3/2/09 10:50 PM Page v
Contents
Preface xxi
About the Authors xxiv
General Introduction 1
I.1 WhatIsManufacturing? 1
I.2 ProductDesignandConcurrentEngineering 8
I.3 Design for Manufacture, Assembly, Disassembly, and Service 11
I.4 GreenDesignandManufacturing 13
I.5 SelectionofMaterials 15
I.6 SelectionofManufacturingProcesses 18
I.7 Computer-integratedManufacturing 26
I.8 QualityAssuranceandTotalQualityManagement 29
I.9 LeanProductionandAgileManufacturing 32
I.10 ManufacturingCostsandGlobalCompetition 32
I.11 GeneralTrendsinManufacturing 34
Part I: Fundamentals of Materials: Their Behavior
and Manufacturing Properties 37
1
The Structure of Metals 40
1.1 Introduction 40
1.2 TypesofAtomicBonds 41
1.3 TheCrystalStructureofMetals 42
1.4 DeformationandStrengthofSingleCrystals 44
1.5 GrainsandGrainBoundaries 47
1.6 PlasticDeformationofPolycrystallineMetals 50
1.7 Recovery,Recrystallization,andGrainGrowth 51
1.8 Cold,Warm,andHotWorking 52
Summary 53 KeyTerms 53 Bibliography 54
ReviewQuestions 54 QualitativeProblems 54
QuantitativeProblems 55 Synthesis,Design,andProjects 55
2
Mechanical Behavior, Testing, and
Manufacturing Properties of Materials 56
2.1 Introduction 56
2.2 Tension 57
2.3 Compression 66
v
A01_KALP1681_06_SE_FM.QXD 2/19/09 2:59 PM Page vi
vi Contents
2.4 Torsion 67
2.5 Bending(Flexure) 68
2.6 Hardness 68
2.7 Fatigue 74
2.8 Creep 75
2.9 Impact 75
2.10 FailureandFractureofMaterialsinManufacturing
andinService 76
2.11 ResidualStresses 81
2.12 Work,Heat,andTemperature 82
Summary 83 KeyTerms 84 Bibliography 84
ReviewQuestions 84 QualitativeProblems 85
QuantitativeProblems 85 Synthesis,Design,andProjects 86
3
Physical Properties of Materials 88
3.1 Introduction 88
3.2 Density 89
3.3 MeltingPoint 92
3.4 SpecificHeat 92
3.5 ThermalConductivity 93
3.6 ThermalExpansion 93
3.7 Electrical,Magnetic,andOpticalProperties 94
3.8 CorrosionResistance 95
Summary 97 KeyTerms 97 Bibliography 98
ReviewQuestions 98 QualitativeProblems 98
QuantitativeProblems 98 Synthesis,Design,andProjects 99
4
Metal Alloys: Their Structure and Strengthening
by Heat Treatment 100
4.1 Introduction 100
4.2 StructureofAlloys 101
4.3 PhaseDiagrams 103
4.4 TheIron–CarbonSystem 107
4.5 TheIron–Iron-carbidePhaseDiagramandtheDevelopment
ofMicrostructuresinSteels 108
4.6 CastIrons 110
4.7 HeatTreatmentofFerrousAlloys 111
4.8 HardenabilityofFerrousAlloys 115
4.9 HeatTreatmentofNonferrousAlloysand
StainlessSteels 117
4.10 CaseHardening 119
4.11 Annealing 121
4.12 Heat-treatingFurnacesandEquipment 123
4.13 DesignConsiderationsforHeatTreating 125
A01_KALP1681_06_SE_FM.QXD 2/19/09 2:59 PM Page vii
Contents vii
Summary 126 KeyTerms 127 Bibliography 127
ReviewQuestions 127 QualitativeProblems 127
QuantitativeProblems 128 Synthesis,Design,andProjects 128
5
Ferrous Metals and Alloys: Production, General
Properties, and Applications 129
5.1 Introduction 129
5.2 ProductionofIronandSteel 130
5.3 CastingofIngots 133
5.4 ContinuousCasting 134
5.5 CarbonandAlloySteels 136
5.6 StainlessSteels 143
5.7 ToolandDieSteels 145
Summary 147 KeyTerms 148 Bibliography 148
ReviewQuestions 148 QualitativeProblems 149
QuantitativeProblems 149 Synthesis,Design,andProjects 150
6
Nonferrous Metals and Alloys: Production,
General Properties, and Applications 151
6.1 Introduction 151
6.2 AluminumandAluminumAlloys 152
6.3 MagnesiumandMagnesiumAlloys 157
6.4 CopperandCopperAlloys 158
6.5 NickelandNickelAlloys 160
6.6 Superalloys 161
6.7 TitaniumandTitaniumAlloys 162
6.8 RefractoryMetalsandAlloys 163
6.9 Beryllium 164
6.10 Zirconium 164
6.11 Low-meltingAlloys 164
6.12 PreciousMetals 166
6.13 Shape-memoryAlloys(SmartMaterials) 166
6.14 AmorphousAlloys(MetallicGlasses) 167
6.15 MetalFoams 167
Summary 168 KeyTerms 168 Bibliography 169
ReviewQuestions 169 QualitativeProblems 169
QuantitativeProblems 170 Synthesis,Design,andProjects 170
7
Polymers: Structure, General Properties,
and Applications 171
7.1 Introduction 171
7.2 TheStructureofPolymers 173
7.3 Thermoplastics 180
7.4 ThermosettingPlastics 184
A01_KALP1681_06_SE_FM.QXD 2/19/09 2:59 PM Page viii
viii Contents
7.5 AdditivesinPlastics 184
7.6 GeneralPropertiesandApplicationsofThermoplastics 185
7.7 GeneralPropertiesandApplicationsofThermosetting
Plastics 188
7.8 BiodegradablePlastics 190
7.9 Elastomers(Rubbers) 191
Summary 192 KeyTerms 193 Bibliography 193
ReviewQuestions 194 QualitativeProblems 194
QuantitativeProblems 195 Synthesis,Design,andProjects 195
8
Ceramics, Graphite, Diamond, and
Nanomaterials: Structure, General Properties,
and Applications 196
8.1 Introduction 196
8.2 TheStructureofCeramics 197
8.3 GeneralPropertiesandApplicationsofCeramics 201
8.4 Glasses 205
8.5 GlassCeramics 207
8.6 Graphite 208
8.7 Diamond 210
8.8 Nanomaterials 210
Summary 212 KeyTerms 212 Bibliography 213
ReviewQuestions 213 QualitativeProblems 214
QuantitativeProblems 214 Synthesis,Design,andProjects 214
9
Composite Materials: Structure, General
Properties, and Applications 216
9.1 Introduction 216
9.2 TheStructureofReinforcedPlastics 217
9.3 PropertiesofReinforcedPlastics 222
9.4 ApplicationsofReinforcedPlastics 225
9.5 Metal-matrixComposites 227
9.6 Ceramic-matrixComposites 229
9.7 OtherComposites 230
Summary 231 KeyTerms 231 Bibliography 231
ReviewQuestions 232 QualitativeProblems 232
QuantitativeProblems 233 Synthesis,Design,andProjects 233
Part II: Metal-Casting Processes
and Equipment 235
10
Fundamentals of Metal Casting 237
10.1 Introduction 237
10.2 SolidificationofMetals 238
A01_KALP1681_06_SE_FM.QXD 2/19/09 2:59 PM Page ix
Contents ix
10.3 FluidFlow 243
10.4 FluidityofMoltenMetal 245
10.5 HeatTransfer 247
10.6 Defects 249
Summary 253 KeyTerms 254 Bibliography 254
ReviewQuestions 254 QualitativeProblems 255
QuantitativeProblems 255 Synthesis,Design,andProjects 256
11
Metal-Casting Processes and Equipment 258
11.1 Introduction 258
11.2 Expendable-mold,Permanent-patternCastingProcesses 262
11.3 Expendable-mold,Expendable-patternCastingProcesses 270
11.4 Permanent-moldCastingProcesses 277
11.5 CastingTechniquesforSingle-crystalComponents 285
11.6 RapidSolidification 286
11.7 InspectionofCastings 287
11.8 MeltingPracticeandFurnaces 287
11.9 FoundriesandFoundryAutomation 289
Summary 289 KeyTerms 290 Bibliography 290
ReviewQuestions 291 QualitativeProblems 291
QuantitativeProblems 292 Synthesis,Design,andProjects 292
12
Metal Casting: Design, Materials,
and Economics 294
12.1 Introduction 294
12.2 DesignConsiderationsinCasting 294
12.3 CastingAlloys 302
12.4 EconomicsofCasting 307
Summary 308 KeyTerms 309 Bibliography 309
ReviewQuestions 309 QualitativeProblems 309
QuantitativeProblems 310 Synthesis,Design,andProjects 310
Part III: Forming and Shaping Processes
and Equipment 313
13
Metal-Rolling Processes and Equipment 316
13.1 Introduction 316
13.2 TheFlat-rollingProcess 318
13.3 Flat-rollingPractice 322
13.4 RollingMills 325
13.5 VariousRollingProcessesandMills 327
Summary 332 KeyTerms 333 Bibliography 333
ReviewQuestions 333 QualitativeProblems 333
QuantitativeProblems 334 Synthesis,Design,andProjects 334