Manufacturing Processes for Engineering Materials

1139 Pages·2016·198.059 MB·English

by  Serope Kalpakjian, Steven Schmid

GLOBAL
EDITION
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Mechanicalpropertiesofselectedalloys.SeeChapter3foradditionaldata.
Ultimate
Yield tensile Elongation Reduction
strength strength in50mm inarea
Digital Resources for Students Identification Conditiona MPa MPa % % Hardness
Alloysteels
AISI4130 Annealed 361 560 28 56 156HB
◦
Q&T205 C 1460 1630 10 41 467HB
AISI4340 Annealed 470 745 22 50 220HB
Your new textbook provides 12-month access to a companion Web site that includes Q&T315◦C 1590 1720 10 40 486HB
Carbonsteels
several manufacturing videos.
◦
AISI1020 Q&T870 C 295 395 37 60 100HB
AISI1040 Annealed 350 520 30 57 150HB
AISI1060 Annealed 372 626 22 38 179HB
Follow the instructions below to register for the companion Web site for Kalpakjian and ◦
AISI1080 Q&T800 C 380 615 25 30 255HB
Schmid’s Manufacturing Processes for Engineering Materials, Sixth Edition in SI Units. Castirons
ASTM20 Ascast — 152 — — 156HB
1. Go to www.pearsonglobaleditions.com. ASTM50 Ascast — 362 — — 262HB
ASTM60-40-18 Annealed 324 448 — — 160HB
2. Enter the title of your textbook or browse by author name. ASTM120-90-02 Q&T 827 965 — — 325HB
Stainlesssteels
3. Click Companion Website.
AISI301 Annealed 205 515 40 — RB85
4. Click Register and follow the on-screen instructions to create a login name 1/8-hard 380 690 40 — RC20
and password. 1/4-hard 515 860 25 — RC25
1/2-hard 758 1034 18 — RC32
Full-hard 965 1276 9 — RC41
AISI304 Annealed 215 505 40 — 201HB
Aluminumalloys
1100 O 35 90 40 — —
H14 120 125 25 — —
(cid:31) 3004 O 69 179 20 — — (cid:31)
H38 234 276 6 — —
5052 O 90 190 25 — —
ISSEPM-PRINK-WOVEN-SPITE-NADIR-RUNES H32 186 234 62 — —
H36 234 269 10
7050 T7651 490 552 — — —
Copperalloys
Redbrass,15%Zn Annealed 91 280 47 — 64HRF
Hard 406 434 5 — 73HRB
Phosphorbronze,5%Sn Annealed 175 350 55 — 40HRB
High-siliconbronze Annealed 210 441 55 — 66HRB
Use the login name and password you created during registration to start using the Titaniumalloys
online resources that accompany your textbook. 99.5%Ti Annealed 240 330 30 — —
Ti-6Al-4V Annealed 925 1000 10 — —
Solution+age 1100 1175 10 — —
IMPORTANT: Note:aQ&T,quenchedandtempered.
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Manufacturing
Processes for
Engineering
Materials
SIXTH
EDITION
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IN SI UNITS
Serope Kalpakjian
Steven R. Schmid
SIContributionsby
K. S. Vijay Sekar
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The rights of Serope Kalpakjian and Steven R. Schmid to be identified as the authors of this work have been asserted by
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Authorized adaptation from the United States edition, entitled Manufacturing Processes for Engineering Materials, 6th
Edition, ISBN 978-0-13-429055-3 by Serope Kalpakjian and Steven R. Schmid published by Pearson Education © 2017.
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Dedication
What can be said about Serope Kalpakjian?
He is a giant of manufacturing research, publishing, and education.
(“But I am so small,” he would say, “far too small to be a giant.”)
Hehaswrittentheworld’smostpopulartextbookforoverthreegener-
ations and has had more influence on training engineers than anyone. He
has won the ASM and SME Gold Medals, indicating the high esteem that
professional societies hold for him, yet he remains humble.
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Universally beloved, Serope can work a room, whether it’s filled with
engineers,scientists,philosophers,orpoets.(Nooneisperfect,hereminds
us.) Everyone is his friend, just as he is everyone’s friend.
He is a phenomenal speaker. I know of no other person that has been
asked to give the commencement address at his own university. He was
askedtogiveaFounder’sLectureatanNAMRCConference,andtoldhe
could speak of whatever he wished: his life as a professor, his 40 years of
writing, his decades of innovative teaching, his cutting-edge research; but
he only had 30 minutes. (“30 minutes? I’ll just speak slowly,” he says.)
He is a devoted husband and father, interested and involved. His chil-
dren and grandchildren have excelled in life—this is perhaps the greatest
measure of man. (“I hated that he asked math questions at dinner,” com-
plains his daughter—a professor at the University of Michigan.) Always
patientandcaring,heexcelledatadvisingstudentsandmentoringfaculty.
Especiallycoauthors.Especiallyme.(“Bookauthorsmakemuchlessthan
those that throw a ball for a living,” he lamented.)
Therearesomepeople,unfortunatelyaveryfew,thatyoumeetinyour
life that you treasure their company and realize that they are genuinely
great;peoplethathavealastinginfluenceonyourlife;peoplethatareyour
life-longfriends.Therearesomepeoplethatyoucanholdasarole-model
and not be disappointed.
That’s Serope.
Sincerely,
Steven Schmid
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Contents
Preface 13
About the Authors 17
1
Introduction 19
1.1 What Is Manufacturing? 19
1.2 Product Design and Concurrent Engineering 25
1.3 Design for Manufacture, Assembly, Disassembly, and
Service 28
1.4 EnvironmentallyConsciousDesign,SustainableManufac-
turing, and Product Life Cycle 30
1.5 Selecting Materials 32
1.6 Selecting Manufacturing Processes 36
1.7 Computer-Integrated Manufacturing 40
1.8 Lean Production and Agile Manufacturing 42
1.9 Quality Assurance and Total Quality Management 43
(cid:2) 1.10 Manufacturing Costs and Global Competitiveness 44 (cid:2)
1.11 General Trends in Manufacturing 46
2
Fundamentals of the Mechanical Behavior
of Materials 48
2.1 Introduction 49
2.2 Tension 50
2.3 Compression 65
2.4 Torsion 68
2.5 Bending 70
2.6 Hardness 71
2.7 Fatigue 76
2.8 Creep 77
2.9 Impact 79
2.10 Residual Stresses 79
2.11 Yield Criteria 83
2.12 Work of Deformation 90
Summary 94 Bibliography 97 Questions 98
Problems 100
5
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6 Contents
3
Structure and Manufacturing Properties
of Metals 104
3.1 Introduction 104
3.2 The Crystal Structure of Metals 105
3.3 Deformation and Strength of Single Crystals 107
3.4 Grains and Grain Boundaries 113
3.5 Plastic Deformation of Polycrystalline Metals 116
3.6 Recovery, Recrystallization, and Grain Growth 117
3.7 Cold, Warm, and Hot Working 119
3.8 Failure and Fracture 119
3.9 Physical Properties 126
3.10 General Properties and Applications of Ferrous
Alloys 131
3.11 General Properties and Applications of Nonferrous
Metals and Alloys 138
Summary 152 Bibliography 153 Questions 154
Problems 156
4
Tribology, Metrology, and Product
Quality 157
(cid:2) 4.1 Introduction 158 (cid:2)
4.2 Surface Structure and Properties 158
4.3 Surface Texture and Roughness 160
4.4 Tribology: Friction, Wear, and Lubrication 164
4.5 Surface Treatments, Coatings, and Cleaning 176
4.6 Engineering Metrology and Instrumentation 189
4.7 Dimensional Tolerances 195
4.8 Testing and Inspection 196
4.9 Quality Assurance 199
Summary 208 Bibliography 210 Questions 211
Problems 212
5
Casting Processes and Heat
Treatment 214
5.1 Introduction 214
5.2 Solidification of Metals 215
5.3 Cast Structures 222
5.4 Fluid Flow and Heat Transfer 227
5.5 Melting Practice and Furnaces 235
5.6 Casting Alloys 237
5.7 Ingot Casting and Continuous Casting 244
5.8 Expendable-Mold, Permanent-Pattern Casting
Processes 246
5.9 Expendable-Mold, Expendable-Pattern Casting
Processes 254
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Contents 7
5.10 Permanent-Mold Casting Processes 258
5.11 Heat Treatment 269
5.12 Design Considerations 280
5.13 Economics of Casting 289
Summary 292 Bibliography 294 Questions 294
Problems 296 Design 299
6
Bulk Deformation Processes 302
6.1 Introduction 303
6.2 Forging 303
6.3 Rolling 328
6.4 Extrusion 349
6.5 Rod, Wire, and Tube Drawing 363
6.6 Swaging 373
6.7 Die-Manufacturing Methods 374
6.8 Die Failures 376
6.9 Economics of Bulk Forming 377
Summary 380 Bibliography 383 Questions 383
Problems 385 Design 390
7
Sheet Metal Processes 391
(cid:2) 7.1 Introduction 392 (cid:2)
7.2 Sheet Metal Characteristics 392
7.3 Shearing 397
7.4 Bending of Sheet and Plate 407
7.5 Miscellaneous Forming Processes 420
7.6 Deep Drawing 437
7.7 Sheet Metal Formability 448
7.8 Equipment for Sheet Metal Forming 454
7.9 Design Considerations 455
7.10 Economics of Sheet Metal Forming 457
Summary 460 Bibliography 462 Questions 462
Problems 464 Design 466
8
Machining Processes 468
8.1 Introduction 469
8.2 Mechanics of Chip Formation 470
8.3 Tool Wear and Failure 494
8.4 Surface Finish and Surface Integrity 501
8.5 Machinability 504
8.6 Cutting-Tool Materials 507
8.7 Cutting Fluids 519
8.8 High-Speed Machining 521
8.9 Cutting Processes and Machine Tools for Producing
Round Shapes 522
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8 Contents
8.10 Cutting Processes and Machine Tools for Producing
Various Shapes 539
8.11 Machining and Turning Centers 554
8.12 Vibration and Chatter 560
8.13 Machine-Tool Structures 562
8.14 Design Considerations 563
8.15 Economics of Machining 565
Summary 571 Bibliography 573 Questions 574
Problems 578 Design 581
9
Abrasive and Other Material Removal
Processes 583
9.1 Introduction 584
9.2 Abrasives 585
9.3 Bonded Abrasives 587
9.4 Mechanics of Grinding 591
9.5 Grinding-Wheel Wear 598
9.6 Grinding Operations and Machines 604
9.7 Finishing Operations 611
9.8 Deburring 616
9.9 Ultrasonic Machining 617
9.10 Chemical Machining 619
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9.11 Electrochemical Machining 623
9.12 Electrochemical Grinding 625
9.13 Electrical-Discharge Machining 627
9.14 High-Energy-Beam Machining 633
9.15 Water-Jet, Abrasive Water-Jet, and Abrasive-Jet
Machining 636
9.16 Hybrid Machining Systems 639
9.17 Design Considerations 640
9.18 Process Economics 642
Summary 646 Bibliography 648 Questions 648
Problems 650 Design 652
10
Polymer Processing and Additive
Manufacturing 654
10.1 Introduction 655
10.2 The Structure of Polymers 657
10.3 Thermoplastics: Behavior and Properties 665
10.4 Thermosets: Behavior and Properties 674
10.5 Thermoplastics: General Characteristics and
Applications 674
10.6 Thermosets: General Characteristics and
Applications 677
10.7 High-Temperature Polymers, Electrically Conducting
Polymers, and Biodegradable Plastics 678
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