كتاب Manufacturing Engineering and Technology 7th Edition
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 كتاب Manufacturing Engineering and Technology 7th Edition

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عدد المساهمات : 14526
التقييم : 23586
تاريخ التسجيل : 01/07/2009
العمر : 29
الدولة : مصر
العمل : مدير منتدى هندسة الإنتاج والتصميم الميكانيكى
الجامعة : المنوفية

مُساهمةموضوع: كتاب Manufacturing Engineering and Technology 7th Edition    الأحد 03 ديسمبر 2017, 5:59 am

أخوانى فى الله
أحضرت لكم كتاب
Manufacturing Engineering and Technology 7th Edition
Serope Kalpakjian
Illinois Institute of Technology
Steven R. Schmid
The University of Notre Dame
SI E dition C ontributions by
K. S. Vijay Sekar
SSN College of Engineering, Chennai, India


ويتناول الموضوعات الأتية :

Contents
Preface xxiii
About the Authors xxvii
General Introduction 1
I.1 What is Manufacturing? 1
I.2 Product Design and Concurrent Engineering 6
I.3 Design for Manufacture, Assembly, Disassembly, and Service 10
I.4 Green Design and Manufacturing 11
I.5 Selection of Materials 13
I.6 Selection of Manufacturing Processes 16
I.7 Computer-integrated Manufacturing 25
I.8 Quality Assurance and Total Quality Management 28
I.9 Lean Production and Agile Manufacturing 30
I.10 Manufacturing Costs and Global Competition 31
I.11 Trends in Manufacturing 32
Part I: Fundamentals of Materials: Behavior
and Manufacturing Properties 35
1 The Structure of Metals 38
1.1 Introduction 38
1.2 Types of Atomic Bonds 39
1.3 The Crystal Structure of Metals 40
1.4 Deformation and Strength of Single Crystals 42
1.5 Grains and Grain Boundaries 45
1.6 Plastic Deformation of Polycrystalline Metals 48
1.7 Recovery, Recrystallization, and Grain Growth 49
1.8 Cold, Warm, and H ot Working 50
Summary 51 Key Terms 51 Bibliography 52
Review Questions 52 Qualitative Problems 52
Quantitative Problems 53 Synthesis, Design, and Projects 54
2 Mechanical Behavior, Testing, and Manufacturing
Properties of Materials 55
2.1 Introduction 55
2.2 Tension 562.3 Compression 65
2.4 Torsion 66
2.5 Bending (Flexure) 67
2.6 Hardness 67
2.7 Fatigue 73
2.8 Creep 74
2.9 Impact 74
2.10 Failure and Fracture of Materials 75
2.11 Residual Stresses 80
2.12 Work, Heat, and Temperature 81
Summary 82 Key Terms 83 Bibliography 83
Review Questions 84 Qualitative Problems 84
Quantitative Problems 85 Synthesis, Design, and Projects 86
3 Physical Properties of Materials 88
3.1 Introduction 88
3.2 Density 89
3.3 Melting Point 92
3.4 Specific Heat 92
3.5 Thermal Conductivity 93
3.6 Thermal Expansion 93
3.7 Electrical, Magnetic, and Optical Properties 94
3.8 Corrosion Resistance 95
Summary 97 Key Terms 98 Bibliography 98
Review Questions 98 Qualitative Problems 98
Quantitative Problems 99 Synthesis, Design, and Projects 99
4 Metal Alloys: Their Structure and Strengthening
by Heat Treatment 101
4.1 Introduction 101
4.2 Structure of Alloys 102
4.3 Phase Diagrams 104
4.4 The Iron–carbon System 107
4.5 The Iron–iron-carbide Phase Diagram and the Development
of Microstructures in Steels 108
4.6 Cast Irons 109
4.7 Heat Treatment of Ferrous Alloys 111
4.8 Hardenability of Ferrous Alloys 113
4.9 Heat Treatment of Nonferrous Alloys
and Stainless Steels 117
4.10 Case Hardening 119
4.11 Annealing 121
4.12 Heat-treating Furnaces and Equipment 123
4.13 Design Considerations for Heat Treating 124Summary 125 Key Terms 126 Bibliography 126
Review Questions 126 Qualitative Problems 127
Quantitative Problems 127 Synthesis, Design, and Projects 127
5 Ferrous Metals and Alloys: Production, General
Properties, and Applications 128
5.1 Introduction 128
5.2 Production of Iron and Steel 129
5.3 Casting of Ingots 132
5.4 Continuous Casting 133
5.5 Carbon and Alloy Steels 135
5.6 Stainless Steels 142
5.7 Tool and Die Steels 144
Summary 145 Key Terms 146 Bibliography 147
Review Questions 147 Qualitative Problems 147
Quantitative Problems 148 Synthesis, Design, and Projects 148
6 Nonferrous Metals and Alloys: Production,
General Properties, and Applications 150
6.1 Introduction 150
6.2 Aluminum and Aluminum Alloys 151
6.3 Magnesium and Magnesium Alloys 155
6.4 Copper and Copper Alloys 156
6.5 Nickel and Nickel Alloys 158
6.6 Superalloys 159
6.7 Titanium and Titanium Alloys 160
6.8 Refractory Metals and Alloys 161
6.9 Beryllium 162
6.10 Zirconium 162
6.11 Low-melting Alloys 162
6.12 Precious Metals 164
6.13 Shape-memory Alloys (Smart Materials) 164
6.14 Amorphous Alloys (Metallic Glasses) 165
6.15 Metal Foams 165
Summary 166 Key Terms 166 Bibliography 166
Review Questions 167 Qualitative Problems 167
Quantitative Problems 167 Synthesis, Design, and Projects 168
7 Polymers: Structure, General Properties,
and Applications 169
7.1 Introduction 169
7.2 The Structure of Polymers 171
7.3 Thermoplastics 1787.4 Thermosetting Plastics 181
7.5 Additives in Plastics 182
7.6 General Properties and Applications
of Thermoplastics 183
7.7 General Properties and Applications
of Thermosetting Plastics 186
7.8 Biodegradable Plastics 187
7.9 Elastomers (Rubbers) 188
Summary 189 Key Terms 190 Bibliography 190
Review Questions 191 Qualitative Problems 191
Quantitative Problems 192 Synthesis, Design, and Projects 193
8 Ceramics, Glass, Graphite, Diamond, and
Nanomaterials: Structure, General Properties,
and Applications 194
8.1 Introduction 194
8.2 The Structure of Ceramics 195
8.3 General Properties and Applications
of Ceramics 200
8.4 Glasses 204
8.5 Glass Ceramics 206
8.6 Graphite 207
8.7 Diamond 209
8.8 Nanomaterials 210
Summary 211 Key Terms 212 Bibliography 212
Review Questions 212 Qualitative Problems 213
Quantitative Problems 213 Synthesis, Design, and Projects 213
9 Composite Materials: Structure, General
Properties, and Applications 215
9.1 Introduction 215
9.2 The Structure of Reinforced Plastics 216
9.3 Properties of Reinforced Plastics 221
9.4 Applications of Reinforced Plastics 224
9.5 Metal-matrix Composites 226
9.6 Ceramic-matrix Composites 228
9.7 Other Composites 229
Summary 230 Key Terms 230 Bibliography 230
Review Questions 231 Qualitative Problems 231
Quantitative Problems 232 Synthesis, Design, and Projects 232Part II: M etal-casting Processes
and Equipment 235
10 Fundamentals of Metal Casting 237
10.1 Introduction 237
10.2 Solidification of Metals 238
10.3 Fluid Flow 243
10.4 Fluidity of Molten Metal 246
10.5 Heat Transfer 247
10.6 Defects 249
Summary 252 Key Terms 252 Bibliography 253
Review Questions 253 Qualitative Problems 253
Quantitative Problems 254 Synthesis, Design, and Projects 255
1 1 Metal-casting Processes and Equipment 256
11.1 Introduction 256
11.2 Expendable-mold, Permanent-pattern Casting
Processes 260
11.3 Expendable-mold, Expendable-pattern Casting
Processes 269
11.4 Permanent-mold Casting Processes 276
11.5 Casting Techniques for Single-crystal Components 284
11.6 Rapid Solidification 286
11.7 Inspection of Castings 287
11.8 Melting Practice and Furnaces 287
11.9 Foundries and Foundry Automation 289
Summary 289 Key Terms 290 Bibliography 290
Review Questions 290 Qualitative Problems 291
Quantitative Problems 291 Synthesis, Design, and Projects 292
12 Metal Casting: Design, Materials,
and Economics 294
12.1 Introduction 294
12.2 Design Considerations in Casting 294
12.3 Casting Alloys 303
12.4 Economics of Casting 308
Summary 309 Key Terms 309 Bibliography 309
Review Questions 310 Qualitative Problems 310
Quantitative Problems 310 Synthesis, Design, and Projects 311Part III: Forming and Shaping Processes
and Equipment 313
13 Metal-rolling Processes and Equipment 316
13.1 Introduction 316
13.2 The Flat-rolling Process 318
13.3 Flat-rolling Practice 323
13.4 Rolling Mills 326
13.5 Various Rolling Processes and Mills 328
Summary 333 Key Terms 333 Bibliography 334
Review Questions 334 Qualitative Problems 334
Quantitative Problems 335 Synthesis, Design, and Projects 336
14 Metal-forging Processes and Equipment 337
14.1 Introduction 337
14.2 Open-die Forging 339
14.3 Impression-die and Closed-die Forging 342
14.4 Various Forging Operations 345
14.5 Forgeability of Metals; Forging Defects 349
14.6 Die Design, Die Materials, and Lubrication 351
14.7 Die-manufacturing Methods and Die Failure 354
14.8 Forging Machines 355
14.9 Economics of Forging 358
Summary 360 Key Terms 361 Bibliography 361
Review Questions 362 Qualitative Problems 362
Quantitative Problems 362 Synthesis, Design, and Projects 363
15 Metal Extrusion and Drawing Processes
and Equipment 364
15.1 Introduction 364
15.2 The Extrusion Process 366
15.3 H ot Extrusion 368
15.4 Cold Extrusion 372
15.5 Extrusion Defects 374
15.6 Design Considerations 376
15.7 Extrusion Equipment 376
15.8 The Drawing Process 377
15.9 Drawing Practice 379
15.10 Drawing Defects and Residual Stresses 382
15.11 Drawing Equipment 382
Summary 383 Key Terms 384 Bibliography 384
Review Questions 384 Qualitative Problems 384
Quantitative Problems 385 Synthesis, Design, and Projects 38516 Sheet-metal Forming Processes
and Equipment 386
16.1 Introduction 386
16.2 Shearing 387
16.3 Sheet-metal Characteristics and Formability 397
16.4 Formability Tests for Sheet Metals 399
16.5 Bending Sheets, Plates, and Tubes 402
16.6 Miscellaneous Bending and Related Forming Operations 406
16.7 Deep Drawing 411
16.8 Rubber Forming and Hydroforming 419
16.9 Spinning 423
16.10 Superplastic Forming 426
16.11 Hot Stamping 427
16.12 Specialized Forming Processes 428
16.13 Manufacturing of Metal Honeycomb Structures 433
16.14 Design Considerations in Sheet-metal Forming 434
16.15 Equipment for Sheet-metal Forming 437
16.16 Economics of Sheet-forming Operations 438
Summary 439 Key Terms 440 Bibliography 440
Review Questions 440 Qualitative Problems 441
Quantitative Problems 441 Synthesis, Design, and Projects 442
1 7 Powder Metal Processes and Equipment 444
17.1 Introduction 444
17.2 Production of Metal Powders 445
17.3 Compaction of Metal Powders 450
17.4 Sintering 461
17.5 Secondary and Finishing Operations 464
17.6 Design Considerations 466
17.7 Economics of Powder Metallurgy 469
Summary 471 Key Terms 471 Bibliography 471
Review Questions 472 Qualitative Problems 472
Quantitative Problems 473 Synthesis, Design, and Projects 473
18 Ceramics, Glasses, and Superconductors:
Processing and Equipment 475
18.1 Introduction 475
18.2 Shaping Ceramics 476
18.3 Forming and Shaping of Glass 483
18.4 Techniques for Strengthening and Annealing Glass 486
18.5 Design Considerations for Ceramics and Glasses 489
18.6 Processing of Superconductors 489Summary 491 Key Terms 491 Bibliography 492
Review Questions 492 Qualitative Problems 492
Quantitative Problems 493 Synthesis, Design, and Projects 493
19 Plastics and Composite Materials: Forming
and Shaping 494
19.1 Introduction 494
19.2 Extrusion 495
19.3 Injection Molding 502
19.4 Blow Molding 509
19.5 Rotational Molding 509
19.6 Thermoforming 511
19.7 Compression Molding 512
19.8 Transfer Molding 513
19.9 Casting 514
19.10 Foam Molding 515
19.11 Cold Forming and Solid-phase Forming 516
19.12 Processing Elastomers 517
19.13 Processing Polymer-matrix Composites 518
19.14 Processing M etal-matrix and Ceramic-matrix
Composites 527
19.15 Design Considerations 528
19.16 Economics of Processing Plastics and Composite
Materials 530
Summary 531 Key Terms 531 Bibliography 532
Review Questions 532 Qualitative Problems 532
Quantitative Problems 533 Synthesis, Design, and Projects 533
20 Rapid-prototyping Processes
and Operations 535
20.1 Introduction 535
20.2 Subtractive Processes 538
20.3 Additive Processes 540
20.4 Virtual Prototyping 551
20.5 Self-replicating Machines 552
20.6 Direct Manufacturing and Rapid Tooling 553
Summary 560 Key Terms 560 Bibliography 560
Review Questions 561 Qualitative Problems 561
Quantitative Problems 562 Synthesis, Design, and Projects 562Part IV: M achining Processes and Machine
Tools 563
21 Fundamentals of Machining 566
21.1 Introduction 566
21.2 Mechanics of Cutting 567
21.3 Cutting Forces and Power 577
21.4 Temperatures in Cutting 580
21.5 Tool Life: Wear and Failure 582
21.6 Surface Finish and Integrity 589
21.7 Machinability 591
Summary 595 Key Terms 596 Bibliography 596
Review Questions 596 Qualitative Problems 597
Quantitative Problems 598 Synthesis, Design, and Projects 599
22 Cutting-tool Materials and Cutting Fluids 600
22.1 Introduction 600
22.2 High-speed Steels 604
22.3 Cast-cobalt Alloys 605
22.4 Carbides 605
22.5 Coated Tools 609
22.6 Alumina-based Ceramics 612
22.7 Cubic Boron Nitride 613
22.8 Silicon-nitride-based Ceramics 614
22.9 Diamond 614
22.10 Whisker-reinforced Materials and Nanomaterials 615
22.11 Tool Costs and Reconditioning of Tools 616
22.12 Cutting Fluids 616
Summary 622 Key Terms 622 Bibliography 622
Review Questions 623 Qualitative Problems 623
Quantitative Problems 624 Synthesis, Design, and Projects 624
23 Machining Processes: Turning and Hole
Making 625
23.1 Introduction 625
23.2 The Turning Process 628
23.3 Lathes and Lathe Operations 636
23.4 Boring and Boring Machines 651
23.5 Drilling, Drills, and Drilling Machines 65223.6 Reaming and Reamers 661
23.7 Tapping and Taps 662
Summary 664 Key Terms 665 Bibliography 665
Review Questions 665 Qualitative Problems 666
Quantitative Problems 666 Synthesis, Design, and Projects 667
24 Machining Processes: Milling, Broaching, Sawing,
Filing, and Gear Manufacturing 668
24.1 Introduction 668
24.2 Milling and Milling Machines 669
24.3 Planing and Shaping 684
24.4 Broaching and Broaching Machines 684
24.5 Sawing 688
24.6 Filing 692
24.7 Gear Manufacturing by Machining 692
Summary 699 Key Terms 700 Bibliography 700
Review Questions 700 Qualitative Problems 700
Quantitative Problems 701 Synthesis, Design, and Projects 702
25 Machining Centers, Machine-tool Structures,
and Machining Economics 703
25.1 Introduction 703
25.2 Machining Centers 703
25.3 Machine-tool Structures 7 12
25.4 Vibration and Chatter in Machining Operations 716
25.5 High-speed Machining 719
25.6 Hard Machining 720
25.7 Ultraprecision Machining 721
25.8 Machining Economics 722
Summary 726 Key Terms 726 Bibliography 727
Review Questions 727 Qualitative Problems 727
Quantitative Problems 728 Synthesis, Design, and Projects 728
26 Abrasive Machining and Finishing
Operations 729
26.1 Introduction 729
26.2 Abrasives and Bonded Abrasives 731
26.3 The Grinding Process 737
26.4 Grinding Operations and Machines 746
26.5 Design Considerations for Grinding 755
26.6 Ultrasonic Machining 755
26.7 Finishing Operations 75626.8 Deburring Operations 761
26.9 Economics of Abrasive Machining and Finishing Operations 764
Summary 765 Key Terms 765 Bibliography 766
Review Questions 766 Qualitative Problems 767
Quantitative Problems 767 Synthesis, Design, and Projects 768
27 Advanced Machining Processes
and Equipment 769
27.1 Introduction 769
27.2 Chemical Machining 770
27.3 Electrochemical Machining 775
27.4 Electrochemical Grinding 779
27.5 Electrical-discharge Machining 780
27.6 Laser-beam Machining 784
27.7 Electron-beam Machining 787
27.8 Water-jet Machining 788
27.9 Abrasive-jet Machining 790
27.10 Hybrid Machining Systems 790
27.11 Economics of Advanced Machining Processes 791
Summary 794 Key Terms 794 Bibliography 795
Review Questions 795 Qualitative Problems 795
Quantitative Problems 796 Synthesis, Design, and Projects 796
Part V: M icrom anufacturing and Fabrication
of M icroelectronic Devices 797
28 Fabrication of Microelectronic Devices 800
28.1 Introduction 800
28.2 Clean Rooms 803
28.3 Semiconductors and Silicon 804
28.4 Crystal Growing and Wafer Preparation 805
28.5 Film Deposition 807
28.6 Oxidation 809
28.7 Lithography 810
28.8 Etching 818
28.9 Diffusion and Ion Implantation 825
28.10 Metallization and Testing 827
28.11 Wire Bonding and Packaging 830
28.12 Yield and Reliability 835
28.13 Printed Circuit Boards 835
Summary 837 Key Terms 838 Bibliography 838
Review Questions 838 Qualitative Problems 839
Quantitative Problems 839 Synthesis, Design, and Projects 84029 Fabrication of Microelectromechanical Devices
and Systems; Nanoscale Manufacturing 841
29.1 Introduction 841
29.2 Micromachining of MEMS Devices 843
29.3 Electroforming-based Processes 854
29.4 Solid Free-form Fabrication of Devices 861
29.5 Nanoscale Manufacturing 866
Summary 869 Key Terms 869 Bibliography 869
Review Questions 870 Qualitative Problems 870
Quantitative Problems 870 Synthesis, Design, and Projects 871
Part VI: Joining Processes and Equipment 873
30 Fusion-welding Processes 877
30.1 Introduction 877
30.2 Oxyfuel–gas Welding 877
30.3 Arc-welding Processes: Nonconsumable Electrode 882
30.4 Arc-welding Processes: Consumable Electrode 885
30.5 Electrodes for Arc Welding 890
30.6 Electron-beam Welding 892
30.7 Laser-beam Welding 893
30.8 Cutting 894
30.9 The Weld Joint, Weld Quality, and Testing 896
30.10 Joint Design and Process Selection 905
Summary 908 Key Terms 909 Bibliography 909
Review Questions 909 Qualitative Problems 910
Quantitative Problems 910 Synthesis, Design, and Projects 911
31 Solid-State Welding Processes 912
31.1 Introduction 912
31.2 Cold Welding and Roll Bonding 913
31.3 Ultrasonic Welding 914
31.4 Friction Welding 915
31.5 Resistance Welding 917
31.6 Explosion Welding 925
31.7 Diffusion Bonding 926
31.8 Economics of Welding Operations 928
Summary 930 Key Terms 930 Bibliography 931
Review Questions 931 Qualitative Problems 931
Quantitative Problems 932 Synthesis, Design, and Projects 93232 Brazing, Soldering, Adhesive-bonding,
and Mechanical Fastening Processes 934
32.1 Introduction 934
32.2 Brazing 935
32.3 Soldering 939
32.4 Adhesive-bonding 943
32.5 Mechanical Fastening 949
32.6 Joining Plastics, Ceramics, and Glasses 953
32.7 Economics of Joining Operations 957
Summary 958 Key Terms 958 Bibliography 959
Review Questions 959 Qualitative Problems 959
Quantitative Problems 960 Synthesis, Design, and Projects 960
Part VII: Surface Technology 961
33 Surface Roughness and Measurement; Friction,
Wear, and Lubrication 963
33.1 Introduction 963
33.2 Surface Structure and Integrity 964
33.3 Surface Texture and Roughness 966
33.4 Friction 969
33.5 Wear 973
33.6 Lubrication 976
33.7 Metalworking Fluids and Their Selection 978
Summary 981 Key Terms 982 Bibliography 982
Review Questions 983 Qualitative Problems 983
Quantitative Problems 984 Synthesis, Design, and Projects 984
34 Surface Treatments, Coatings, and Cleaning 985
34.1 Introduction 985
34.2 Mechanical Surface Treatments 986
34.3 Mechanical Plating and Cladding 987
34.4 Case Hardening and Hard Facing 988
34.5 Thermal Spraying 988
34.6 Vapor Deposition 989
34.7 Ion Implantation and Diffusion Coating 993
34.8 Laser Treatments 993
34.9 Electroplating, Electroless Plating, and Electroforming 994
34.10 Conversion Coatings 998
34.11 Hot Dipping 998
34.12 Porcelain Enameling; Ceramic and Organic Coatings 99934.13 Diamond Coating and Diamond-like Carbon 1000
34.14 Surface Texturing 1001
34.15 Painting 1001
34.16 Cleaning of Surfaces 1002
Summary 1004 Key Terms 1004 Bibliography 1004
Review Questions 1005 Qualitative Problems 1005
Quantitative Problems 1005 Synthesis, Design, and Projects 1005
Part VIII: Engineering M etrology,
Instrumentation, and Q uality
Assurance 1007
35 Engineering Metrology and
Instrumentation 1008
35.1 Introduction 1008
35.2 Measurement Standards 1008
35.3 Geometric Features of Parts: Analog and Digital
Measurements 1010
35.4 Traditional Measuring Methods and Instruments 1010
35.5 Modern Measuring Instruments and Machines 1017
35.6 Automated Measurement 1020
35.7 General Characteristics and Selection of Measuring
Instruments 1021
35.8 Geometric Dimensioning and Tolerancing 1021
Summary 1027 Key Terms 1027 Bibliography 1027
Review Questions 1028 Qualitative Problems 1028
Quantitative Problems 1029 Synthesis, Design, and Projects 1029
36 Quality Assurance, Testing,
and Inspection 1030
36.1 Introduction 1030
36.2 Product Quality 1031
36.3 Quality Assurance 1031
36.4 Total Quality Management 1032
36.5 Taguchi Methods 1034
36.6 The ISO and QS Standards 1038
36.7 Statistical Methods of Quality Control 1039
36.8 Statistical Process Control 1042
36.9 Reliability of Products and Processes 1048
36.10 Nondestructive Testing 1048
36.11 Destructive Testing 1052
36.12 Automated Inspection 1052Summary 1053 Key Terms 1054 Bibliography 1054
Review Questions 1054 Qualitative Problems 1055
Quantitative Problems 1055 Synthesis, Design, and Projects 1056
Part IX: Manufacturing in a Com petitive
Environment 1057
37 Automation of Manufacturing Processes
and Operations 1059
37.1 Introduction 1059
37.2 Automation 1061
37.3 Numerical Control 1068
37.4 Adaptive Control 1074
37.5 Material Handling and Movement 1077
37.6 Industrial Robots 1078
37.7 Sensor Technology 1085
37.8 Flexible Fixturing 1089
37.9 Assembly Systems 1090
37.10 Design Considerations for Fixturing, Assembly, Disassembly,
and Servicing 1094
37.11 Economic Considerations 1096
Summary 1097 Key Terms 1098 Bibliography 1098
Review Questions 1098 Qualitative Problems 1099
Quantitative Problems 1099 Synthesis, Design, and Projects 1099
38 Computer-aided Manufacturing 1101
38.1 Introduction 1101
38.2 Manufacturing Systems 1102
38.3 Computer-integrated Manufacturing 1102
38.4 Computer-aided Design and Engineering 1105
38.5 Computer-aided Manufacturing 1110
38.6 Computer-aided Process Planning 1110
38.7 Computer Simulation of Manufacturing Processes and
Systems 1113
38.8 Group Technology 1114
Summary 1122 Key Terms 1122 Bibliography 1122
Review Questions 1123 Qualitative Problems 1123
Synthesis, Design, and Projects 1123
39 Computer-integrated Manufacturing
Systems 1124
39.1 Introduction 1124
39.2 Cellular Manufacturing 112539.3 Flexible Manufacturing Systems 1126
39.4 Holonic Manufacturing 1129
39.5 Just-in-time Production 1131
39.6 Lean Manufacturing 1132
39.7 Communications Networks in Manufacturing 1134
39.8 Artificial Intelligence 1135
39.9 Economic Considerations 1138
Summary 1138 Key Terms 1139 Bibliography 1139
Review Questions 1139 Qualitative Problems 1140
Synthesis, Design, and Projects 1140
40 Product Design and Manufacturing in
a Competitive Environment 1141
40.1 Introduction 1141
40.2 Product Design 1142
40.3 Product Quality 1145
40.4 Life-cycle Assessment and Sustainable Manufacturing 1145
40.5 Energy Consumption in Manufacturing 1147
40.6 Material Selection for Products 1149
40.7 Material Substitution 1151
40.8 Manufacturing Process Capabilities 1153
40.9 Process Selection 1155
40.10 Manufacturing Costs and Cost Reduction 1158
Summary 1162 Key Terms 1162 Bibliography 1162
Review Questions 1163 Qualitative Problems 1163
Synthesis, Design, and Projects 1164
Index 1167
Case Studies
I.1: Baseball Bats 15
I.2: U.S. Pennies 16
I.3: Saltshaker and Pepper Mill 24
I.4: Mold for Making Sunglass Frames 27
3.1: Selection of Materials for Coins 97
5.1: Advanced H igh-strength Steels in Automobiles 142
5.2: Stainless Steels in Automobiles 144
6.1: An All-aluminum Automobile 154
7.1: Dental and Medical Bone Cement 175
7.2: Use of Electrically Conducting Polymers in Rechargeable
Batteries 181
7.3: Materials for a Refrigerator Door Liner 187
8.1: Ceramic Knives 198
8.2: Ceramic Gun Barrels 203
8.3: Ceramic Ball and Roller Bearings 203
9.1: Composite Military Helmets and Body Armor 225
9.2: Aluminum-matrix Composite Brake Calipers 227
9.3: Composites in the Aircraft Industry 229
11.1: Lost-foam Casting of Engine Blocks 270
11.2: Investment-cast Superalloy Components for Gas Turbines 273
11.3: Investment Casting of Total Knee Replacements 274
11.4: Die Casting of a Headlight M ount 281
12.1: Illustrations of Poor and Good Casting Designs 301
14.1: Manufacture of a Stepped Pin by Heading and Piercing
Operations 347
14.2: Suspension Components for the Lotus Elise Automobile 359
15.1: Manufacture of Aluminum Heat Sinks 371
15.2: Cold-extruded Part 373
16.1: Tailor-welded Sheet Metal for Automotive Applications 393
16.2: Manufacturing of Food and Beverage Cans 418
16.3: Tube Hydroforming of an Automotive Radiator Closure 421
16.4: Cymbal Manufacture 431
17.1: H ot Isostatic Pressing of a Valve Lifter 456
17.2: Mobile Phone Components Produced by Metal Injection
Molding 458
17.3: Powder Metallurgy Parts in a Snowblower 470
18.1: Production of High-temperature Superconducting Tapes 490
19.1: Polymer Automotive-body Panels Shaped by Various
Processes 524
19.2: Manufacture of Head Protector®️ Tennis Racquets 525
19.3: Metal-matrix Composite Brake Rotors and Cylinder Liners 527
20.1: Functional Rapid Prototyping 536
20.2: Coffeemaker Design 544
20.3: Production of Second Life Avatars 547
20.4: Fuselage Fitting for Helicopters 548
20.5: Invisalign®️ Orthodontic Aligners 553
20.6: Casting of Plumbing Fixtures 558
23.1: Brake Disk Machining 635
23.2: Bone Screw Retainer 663
24.1: Broaching Internal Splines 68724.2: Ping Golf Putters 690
25.1: Machining Outer Bearing Races on a Turning Center 710
27.1: Electrochemical Machining of a Biomedical Implant 777
27.2: Manufacture of Small Satellites 791
29.1: Digital Micromirror Device 847
29.2: Accelerometer for Automotive Air Bags 862
31.1: Friction Welding of Pistons 929
32.1: Light Curing Acrylic Adhesives for Medical Products 955
36.1: Manufacture of Television Sets by Sony Corporation 1036
y Sony Corp
37.1: Robotic Deburring of a Blow-molded Toboggan 1084


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