Manufacturing processes & materials

865 Pages·2000·56.896 MB·English

by  Doyle, Lawrence E., Elshennawy, Ahmad K., Schrader, George F

Manufacturing
About the Book
Processes & Materials
Anyone working in a technical department of a manufacturing company—regard-
less of education, experience, and skill level—needs a basic understanding of
manufacturing processes and equipment. Whether used as a text at the college
Fourth Edition
or university level, as a reference for professionals in the field, or as an introduc-
tory guide for plant-floor personnel, Manufacturing Processes & Materials is P
designed to provide that necessary foundation knowledge.
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The book covers the basic processes and machinery used in the job shop, tool- o
room, or small manufacturing facility. At the same time, it describes advanced
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equipment used in larger production environments. The reader is given a thor- a
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ough review of metals and other engineering materials, including their physical
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properties, testing, treatment, and suitability for use in manufacturing. Quality, s
measurement and gaging, process planning, and manufacturing systems are all
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addressed.
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Questions and problems at the end of each chapter can be used as a self-test or s f
as assignments in the classroom environment. An Instructor’s Guide is avail- a
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able to tailor a more structured learning experience. Manufacturing Processes &
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Materials contains 31 chapters with 45 tables, 586 illustrations, 141 equations,

and an extensive index, making it one of the most comprehensive texts available
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on the subject.
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This new edition is an extensive revision of the highly regarded text first com- a
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piled by Professor Lawrence E. Doyle and contributing authors. Professors
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George Schrader and Ahmad Elshennawy of the University of Central Florida e i
have ably piloted the research and writing of the revised book. n
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s
Fourth
Edition
Schrader
Elshennawy
Society of George F. Schrader
Society of
Manufacturing Engineers
Manufacturing Engineers
www.sme.org Ahmad K. Elshennawy
www.sme.org
Manufacturing
Processes & Materials
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Manufacturing
Processes & Materials
Fourth Edition
George F. Schrader
Ahmad K. Elshennawy
Society of Manufacturing Engineers
Dearborn, Michigan
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Copyright © 2000 by Society of Manufacturing Engineers
Based on Manufacturing Processes and Materials for Engi-
neers previously published by Prentice-Hall, Inc.
987654321
All rights reserved, including those of translation. This book,
or parts thereof, may not be reproduced by any means, includ-
ing photocopying, recording or microfilming, or by any infor-
mation storage and retrieval system, without permission in
writing of the copyright owners.
No liability is assumed by the publisher with respect to use of
information contained herein. While every precaution has been
taken in the preparation of this book, the publisher assumes
no responsibility for errors or omissions. Publication of any
data in this book does not constitute a recommendation or
endorsement of any patent, proprietary right, or product that
may be involved.
Library of Congress Catalog Card Number: 00-131494
International Standard Book Number: 0-87263-517-1
Additional copies may be obtained by contacting:
Society of Manufacturing Engineers
Customer Service
One SME Drive, P.O. Box 930
Dearborn, Michigan 48121
1-800-733-4763
www.sme.org
SME staff who participated in producing this book:
Millicent Treloar, Senior Editor
Rosemary Csizmadia, Production Supervisor
Frances Kania, Production Assistant
Kathye Quirk, Production Assistant/Cover Design
Cover photo courtesy of Precision Balancing & Analyzing Co.,
Machine Tool Spindle Repairs & New Spindles
Printed in the United States of America
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About the Authors
Co-authors George F. Schrader and Ahmad K. Dr. Elshennawy, currently an Associate Pro-
Elshennawy have the wealth of practical expe- fessor in the Department of Industrial Engineer-
rience and technical knowledge of manufactur- ing and Management Systems at the University
ing processes necessary for the compilation of a of Central Florida, has an educational back-
comprehensive text on the subject. ground in production engineering and industrial
Dr. Schrader, currently Professor of Engi- engineering. Since 1978 he has taught many
neering, Emeritus, at the University of Central courses on manufacturing and manufacturing-
Florida in Orlando, has an educational back- related subjects at Alexandria University in
ground in mechanical engineering, applied math- Egypt, Pennsylvania State University, and the
ematics, and industrial engineering. Since 1945 University of Central Florida. Dr. Elshennawy’s
he has taught a variety of courses and coordi- greatest expertise is in the area of precision mea-
nated laboratory exercises on the subject of surement and manufacturing automation, sub-
manufacturing at several major universities in ject areas in which he acquired considerable
the U.S. In addition to his academic work, he experience while working at the National Insti-
has served as a consultant to many manufactur- tute of Standards and Technology (NIST) in
ing industries and worked with a number of tech- Gaithersburg, Maryland.
nical societies on industry-related activities.
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Table of Contents
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1.1 Manufacturing .......................................................................................................1
1.2 Hand Tools to Machine Tools...................................................................................1
1.2.1 Early Hand Tools, 1.2.2 The Iron Age, 1.2.3 Industrial Revolution, 1.2.4 Automation
1.3 Types of Products....................................................................................................5
1.4 Organization for Manufacturing..............................................................................5
1.4.1 Types of Manufacturing Systems, 1.4.2 Small Organizations,
1.4.3 Large Organizations, 1.4.4 Manufacturing Engineering
1.5 Questions............................................................................................................10
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2.1 Importance of Manufacturing as an Economic Activity ............................................13
2.2 State of the Industry..............................................................................................13
2.3 Labor Productivity.................................................................................................14
2.4 International Competitiveness ...............................................................................16
2.4.1 Balance of Trade, 2.4.2 Trade Agreements
2.5 Manufacturing Innovations ...................................................................................18
2.5.1 Machine Tools, 2.5.2 Manufacturing Systems
2.6 Questions............................................................................................................21
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3.1 Metal Structures ...................................................................................................23
3.1.1 Unit Cells, 3.1.2 Changes in Crystal Structure, 3.1.3 Crystalline Structure and
Physical Properties, 3.1.4 Fracture
3.2 Fundamentals of Metal Alloys ...............................................................................27
3.2.1 Metallic Solid Solutions and Compounds, 3.2.2 How Alloys Melt, 3.2.3 Equilibrium
Diagrams, 3.2.4 Alloys in the Solid State, 3.2.5 Grain Growth
3.3 Metallurgy of Iron and Steel..................................................................................33
3.3.1 Iron and Iron Carbide Solid Solutions, 3.3.2 Pearlite, 3.3.3 Hypoeutectoid and
Hypereutectoid Steels, 3.3.4 Martensite, 3.3.5 Other Structures of Steel, 3.3.6 Practical
Aspects of Carbon in Steel, 3.3.7 Grain Size of Steel, 3.3.8 Solidification of Cast Iron
3.4 Testing of Engineering Materials............................................................................38
3.4.1 Tension Test, 3.4.2 Hardness Testing, 3.4.3 Notched-bar Impact Testing, 3.4.4 Bend
Tests, 3.4.5 High-temperature Tests, 3.4.6 Fatigue Testing, 3.4.7 Fracture Toughness Tests,
3.4.8 Nondestructive Testing, 3.4.9 Corrosion Testing
3.5 Questions............................................................................................................52
3.6 Problems .............................................................................................................53
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4.1 Iron, Steel, and Power ..........................................................................................57
4.2 Iron Making.........................................................................................................57
4.3 The Blast Furnace and its Chemistry ......................................................................59
4.4 Steelmaking.........................................................................................................59
4.4.1 The Basic Oxygen Process, 4.4.2 The Electric-furnace Process
4.5 Finishing and Ingot Teeming .................................................................................64
4.6 Special Techniques in Steel Refining.......................................................................65
4.7 Aluminum............................................................................................................65
4.8 Copper ...............................................................................................................66
4.9 Miscellaneous Metals............................................................................................68
4.9.1 Magnesium, 4.9.2 Zinc, 4.9.3 Lead, 4.9.4 Tin, 4.9.5 Titanium, 4.9.6 Tungsten
4.10 Steel..................................................................................................................69
4.11 Effects of Alloying Elements in Ferrous Alloys........................................................69
4.12 Carbon Steels....................................................................................................71
4.13 Alloy Steels ........................................................................................................72
4.14 Questions..........................................................................................................76
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5.1 Effects of Alloying on Properties.............................................................................79
5.2 Aluminum............................................................................................................80
5.2.1 Aluminum Alloys
5.3 Magnesium .........................................................................................................81
5.3.1 Magnesium Alloys
5.4 Copper ...............................................................................................................83
5.4.1 Copper Alloys
5.5 Zinc.....................................................................................................................84
5.5.1 Zinc Alloys
5.6 Titanium..............................................................................................................85
5.6.1 Titanium Alloys
5.7 Nickel and its Alloys .............................................................................................86
5.8 The White Metals .................................................................................................86
5.9 Refractory Metals .................................................................................................86
5.10 Precious Metals..................................................................................................87
5.11 Questions..........................................................................................................87
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6.1 Heat Treatment Principles......................................................................................89
6.2 Heat Treatment of Nonallotropic Alloys..................................................................90
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6.3 Heat Treatment Processes for Steels .......................................................................91
6.3.1 Steel Hardening, 6.3.2 Annealing of Steel
6.4 Surface-hardening of Steel ...................................................................................99
6.4.1 Induction-hardening, 6.4.2 Flame-hardening, 6.4.3 Comparison of Methods,
6.4.4 Carburizing to Case-harden, 6.4.5 Cyaniding, 6.4.6 Nitriding, 6.4.7 Laser Beam
Hardening, 6.4.8 Electron Beam Hardening
6.5 Heat Treatment of Nonferrous Metals ..................................................................103
6.6 Heat-treating Furnaces .......................................................................................103
6.6.1 Hearth Furnaces, 6.6.2 Rotary Furnaces, 6.6.3 Continuous Furnaces, 6.6.4 Furnace
Atmospheres, 6.6.5 Molten Baths for Heat Treating, 6.6.6 Bath Furnaces
6.7 Design Considerations for Heat Treatment...........................................................109
6.8 Cost Considerations...........................................................................................109
6.9 Process Automation............................................................................................109
6.10 Questions........................................................................................................109
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7.1 Nonmetallic Material Families.............................................................................111
7.2 Plastic Materials .................................................................................................112
7.2.1 Resins and Polymers, 7.2.2 Additives, 7.2.3 Plastic Products, 7.2.4 Thermosetting
Plastics, 7.2.5 Thermoplastics, 7.2.6 Elastomers (Rubbers), 7.2.7 Silicones, 7.2.8 Adhesives
7.3 Plastics Processing..............................................................................................126
7.3.1 Compression Molding, 7.3.2 Transfer Molding, 7.3.3 Injection Molding,
7.3.4 Casting, 7.3.5 Extrusion and Pultrusion, 7.3.6 Foams, 7.3.7 Laminates and
Reinforced Plastic Molding, 7.3.8 Forming Plastic Sheets, 7.3.9 Shell Molding,
7.3.10 Joining Plastics, 7.3.11 Machining Plastics, 7.3.12 Rubber Processing
7.4 Design of Molded Plastic Parts.............................................................................135
7.5 Ceramics...........................................................................................................136
7.5.1 Structure, 7.5.2 Clay Products, 7.5.3 Refractory Materials,,,,, 7.5.4 Glass,
7.5.5 Cermets, 7.5.6 Mechanical and Electrical Applications, 7.5.7 Ceramic Cutting Tools
7.6 Questions..........................................................................................................138
7.7 Problems ...........................................................................................................139
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8.1 Sand Casting Principles ......................................................................................141
8.1.1 The Behavior of Cast Metal, 8.1.2 The Mold and Its Components
8.2 Making Molds....................................................................................................146
8.2.1 Hand Tools for Molding, 8.2.2 Mold-making Steps, 8.2.3 Molding Machines
8.3 Cores................................................................................................................149
8.3.1 Core Making
8.4 Patterns .............................................................................................................153
8.4.1 Types, 8.4.2 Material, 8.4.3 Layout, 8.4.4 Shrinkage Allowance, 8.4.5 Other
Allowances, 8.4.6 Draft, 8.4.7 Fillets, 8.4.8 Locating Pads, 8.4.9 Color Coding
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