Manufacturing Engineering and Technology - Pearson

1 A01 KALP860908 SEFM page iManufacturingEngineeringand Technology EIGHTHEDITIONS erope KalpakjianIllinois Institute of TechnologySteven R. SchmidThe University of Notre DameA01 KALP860908 SEFM page iiSenior Vice President Courseware Portfolio Management:Marcia J. HortonVice President Portfolio Management Engineering & Computer Science, Global Editions:Julian PartridgeExecutive Portfolio Manager:Holly StarkPortfolio Management Assistant:Amanda PerfitField Marketing Manager:Demetrius HallProduct Marketing Manager:Yvonne VannattaMarketing Assistant:Jon BryantManager, Rights and Permissions:Ben FerriniManaging Producer:Scott DisannoContent Producer:Amanda BrandsSenior Digital Content Producer:Sandra RodriguezInventory Manager:Bruce BoundyCover Designer:Black Horse DesignsCover Photo:Getty Images/Olaf Pappers/EyeEmComposition:Integra Software Services Pvt.

2 Manager:Yohalakshmi Segar, IntegraCopyrightc 2020, 2014, 2010, 2006 by Pearson , Hoboken, NJ 07030 All rights reserved. Printed in the United States of America. This publication is protected by copyright, and permission should be obtained from thepublisher prior to any prohibited reproduction, storage in a retrieval system, or transmission in any form or by any means, electronic, mechanical,photocopying, recording, or otherwise. For information regarding permissions, request forms and the appropriate contacts within the PearsonEducation Global Rights & Permissions department, please visit of the designations by manufacturers and seller to distinguish their products are claimed as trademarks. Where those designations appear in thisbook, and the publisher was aware of a trademark claim, the designations have been printed in initial caps or all author and publisher of this book have used their best efforts in preparing this book.

3 These efforts include the development, research, and testingoftheories and programs to determine their effectiveness. The author and publisher make no warranty of any kind, expressed or implied, with regard tothese programs or the documentation contained in this book. The author and publisher shall not be liable in any event for incidental or consequentialdamages with, or arising out of, the furnishing, performance, or use of these of Congress Cataloging-in-Publication DataKalpakjian, Serope, 1928- Manufacturing Engineering and Technology / Serope Kalpakjian, Illinois Institute of Technology , Steven R. Schmid,The University of Notre Dame. Eighth cmISBN-13: 978-0-13-522860-9 ISBN-10: 0-13-522860-31. Production Engineering . 2. Manufacturing processes.

4 I. Schmid, Steven R. II. dc23 ISBN-13: 978-0-13-522860-9 ISBN-10:0-13-522860-3A01 KALP860908 SEFM page iiiDedicated to our families, whose patience andsupport made this book ivA01 KALP860908 SEFM page vContents PrefacexxiiiAbout the AuthorsxxviGeneral is Manufacturing ? Design and Concurrent for Manufacture, Assembly, Disassembly, and Conscious Design, Sustainable Manufacturing ,and Product Life of of Manufacturing Assurance and Total Quality Production and Agile Costs and Global in Manufacturing33 Part I:Fundamentals of Materials: Behaviorand Manufacturing Properties351 The Structure of of Atomic Crystal Structure of and Strength of Single and Grain Deformation of Polycrystalline , Recrystallization, and Grain , Warm, and Hot Working50 Summary 51 Key Terms 51 Bibliography 52 Review Questions 52 Qualitative Problems 53 Quantitative Problems 54 Synthesis, Design, and Projects 552 Mechanical Behavior, Testing, and ManufacturingProperties of (Flexure)

5 And Fracture of , Heat, and Temperature88 Summary 88 Key Terms 89 Bibliography 90 Review Questions 90 Qualitative Problems 91 Quantitative Problems 93 Synthesis, Design, and Projects 953 Physical Properties of , Magnetic, and Optical Resistance104 Summary 106 Key Terms 106 Bibliography 107 Review Questions 107 Qualitative Problems 107 Quantitative Problems 108 Synthesis, Design, and Projects 1094 Metal Alloys: Their Structure and Strengtheningby Heat of Iron-Carbon Iron Iron-carbide Phase Diagram and the Development of Microstructuresin Steels Treatment of Ferrous of Ferrous Treatment of Nonferrous Alloys and Stainless Furnaces and Considerations for Heat Treating134A01 KALP860908 SEFM page viiContentsviiSummary 134 Key Terms 135 Bibliography 136 Review Questions 136 Qualitative Problems 137 Quantitative Problems 137 Synthesis, Design, and Projects 1385 Ferrous Metals and Alloys.

6 Production, GeneralProperties, and of Iron and of and Alloy and Die Steels155 Summary 157 Key Terms 158 Bibliography 158 Review Questions 159 Qualitative Problems 159 Quantitative Problems 160 Synthesis, Design, and Projects 1606 Nonferrous Metals and Alloys:Production, General Properties,and and Aluminum and Magnesium and Copper and Nickel and Titanium Metals and Alloys (Smart Materials) Alloys (Metallic Glasses) Foams and Earth Metals179 Summary 179 Key Terms 180 Bibliography 180 Review Questions 181 Qualitative Problems 181 Quantitative Problems 182 Synthesis, Design, and Projects 182A01 KALP860908 SEFM page viiiviiiContents7 Polymers: Structure, General Properties,and Structure of in Properties and Applications of Properties and Applications of Thermosetting (Rubbers) 205 Key Terms 206 Bibliography 207 Review Questions 207 Qualitative Problems 208 Quantitative Problems 209 Synthesis, Design, and Projects 2098 Ceramics, Glass, Graphite, Diamond, andNanomaterials: Structure, General Properties,and Structure of Properties and Applications of 227 Key Terms 228 Bibliography 228 Review Questions 229 Qualitative Problems 230 Quantitative Problems 230 Synthesis, Design, and Projects 2319 Composite Materials.

7 Structure, GeneralProperties, and Structure of Reinforced of Reinforced of Reinforced Composites245 Summary 246 Key Terms 247 Bibliography 247 Review Questions 248 Qualitative Problems 248 Quantitative Problems 249 Synthesis, Design, and Projects 250A01 KALP860908 SEFM page ixContentsixPart II:Metal-casting Processesand Equipment25310 Fundamentals of Metal of of Molten 272 Key Terms 273 Bibliography 273 Review Questions 274 Qualitative Problems 274 Quantitative Problems 276 Synthesis, Design, and Projects 27711 Metal-casting Processes and , Permanent-pattern Casting , Expendable-pattern Casting Casting Techniques for Single-crystal of Practice and and Foundry Automation309 Summary 309 Key Terms 310 Bibliography 310 Review Questions 311 Qualitative Problems 311 Quantitative Problems 312 Synthesis, Design, and Projects 31412 Metal Casting.

8 Design, Materials,and Economics Considerations in of Casting330 Summary 330 Key Terms 331 Bibliography 331 Review Questions 331 Qualitative Problems 332 Quantitative Problems 332 Synthesis, Design, and Projects 333A01 KALP860908 SEFM page xxContentsPart III: forming and Shaping Processesand Equipment33713 Metal-rolling Processes and Flat-rolling Rolling Processes and Mills352 Summary 357 Key Terms 358 Bibliography 358 Review Questions 359 Qualitative Problems 359 Quantitative Problems 360 Synthesis, Design, and Projects 36114 Metal-forging Processes and and Closed-die Forging of Metals; Forging Defects Design, Die Materials, and Methods and Die of Forging382 Summary 386 Key Terms 386 Bibliography 387 Review Questions 387 Qualitative Problems 387 Quantitative Problems 388 Synthesis, Design, and Projects 38915 Metal Extrusion and Drawing Processesand Extrusion Defects Drawing Defects and Residual Equipment410 Summary 412 Key Terms 412 Bibliography 412 Review Questions 413 Qualitative Problems 413 Quantitative Problems 414 Synthesis, Design, and Projects 415A01 KALP860908 SEFM page xiContentsxi16 Sheet-Metal forming Processesand Characteristics and Tests for Sheet Sheets, Plates.

9 And Bending and Related forming forming and forming of Metal Honeycomb Considerations in Sheet-metal for Sheet-metal of Sheet- forming Operations471 Summary 472 Key Terms 473 Bibliography 474 Review Questions 474 Qualitative Problems 475 Quantitative Problems 476 Synthesis, Design, and Projects 47817 Powder-Metal Processes and of Metal of Metal and Finishing of Powder Metallurgy504 Summary 508 Key Terms 508 Bibliography 509 Review Questions 509 Qualitative Problems 510 Quantitative Problems 510 Synthesis, Design, and Projects 51118 Ceramics, Glasses, and Superconductors:Processing and and Shaping of for Strengthening and Annealing Considerations for Ceramics and of Superconductors528A01 KALP860908 SEFM page xiixiiContentsSummary 529 Key Terms 530 Bibliography 530 Review Questions 530 Qualitative Problems 531 Quantitative Problems 532 Synthesis, Design, and Projects 53219 Plastics and Composite Materials.

10 Formingand forming and Solid-phase Polymer-Matrix Metal-Matrix and Ceramic-Matrix of Processing Plastics and Composite Materials568 Summary 569 Key Terms 569 Bibliography 570 Review Questions 571 Qualitative Problems 571 Quantitative Problems 572 Synthesis, Design, and Projects 57220 Additive Manufacturing Jetting Bed AM Manufacturing and Rapid for Additive Manufacturing Economics600 Summary 603 Key Terms 603 Bibliography 604 Review Questions 604 Qualitative Problems 605 Quantitative Problems 605 Synthesis, Design, and Projects 606A01 KALP860908 SEFM page xiiiContentsxiiiPart IV:Machining Processes and MachineTools60721 Fundamentals of of Forces and Power in Life: Wear and Finish and 641 Key Terms 642 Bibliography 642 Review Questions 643 Qualitative Problems 643 Quantitative Problems 645 Synthesis, Design, and Projects 64722 Cutting-Tool Materials and Boron Nitride Materials and Costs and Reconditioning of Fluids663 Summary 668 Key Terms 669 Bibliography 669 Review Questions 670 Qualitative Problems 670 Quantitative Problems 671 Synthesis, Design, and Projects 67223 Machining Processes.