Materials and processes in manufacturing / E. Paul Degarmo [and others].

Edition
  • 9th ed.
Published
  • New York : Wiley ©2003
Physical description
xiv, 1154 pages : illustrations ; 29 cm
ISBN
  • 0471033065
  • 9780471033066
  • 0471656534
  • 9780471656531
Notes
  • Includes bibliographical references and index.
  • Previous ed.: 1999
Contents
  • Preface -- Chapter 1: Introduction to materials and processes in manufacturing: -- 1-1: Materials, manufacturing, and the standard of living -- 1-2: Manufacturing and production systems -- 1-3: Language of manufacturing or process technology -- 1-4: Product life cycle and life-cycle cost -- 1-5: Manufacturing system design -- Materials: -- Chapter 2: Properties of materials: -- 2-1: Introduction -- 2-2: Static properties -- 2-3: Dynamic properties -- 2-4: Temperature effects -- 2-5: Machinability, formability and weldability -- 2-6: Fracture toughness and the fracture mechanics approach -- 2-7: Physical properties -- Case Study: Overhead conveyor for meat processing -- Chapter 3: Nature of metals and alloys: -- 3-1: Structure-property relationships -- 3-2: Structure of atoms -- 3-3: Atomic bonding -- 3-4: Secondary bonds -- 3-5: Interatomic distances and size of atoms -- 3-6: Atom arrangements in materials -- 3-7: Crystal structures of metals -- 3-8: Development of a grain structure -- 3-9: Elastic deformation -- 3-10: Plastic deformation -- 3-11: Dislocation theory of slippage -- 3-12: Strain hardening or work hardening -- 3-13: Plastic deformation in polycrystalline metals -- 3-14: Grain shape and anisotropic properties -- 3-15: Fracture of metals -- 3-16: Cold working, recrystallization, and hot working -- 3-17: Grain growth -- 3-18: Alloys and alloy types -- 3-19: Atomic structure and electrical properties -- Case Study: Window frame materials and design -- Chapter 4: Equilibrium phase diagrams and the iron-carbon system: -- 4-1: Introduction -- 4-2: Phases -- 4-3: Equilibrium phase diagrams -- 4-4: Iron-carbon equilibrium diagram -- 4-5: Steels and the simplified iron-carbon diagram -- 4-6: Cast irons -- Case Study: Blacksmith anvils -- Chapter 5: Heat treatment: -- 5-1: Introduction -- 5-2: Processing heat treatments -- 5-3: Heat treatments used to increase strength -- 5-4: Strengthening heat treatments for nonferrous metals -- 5-5: Strengthening heat treatments for steel -- 5-6: Surface hardening of steel -- 5-7: Furnaces -- 5-8: Heat treatment and energy -- Case Study: Flying chip from a sledgehammer.
  • Chapter 6: Ferrous metals and alloys: -- 6-1: Introduction to history-dependent materials -- 6-2: Iron -- 6-3: Steel -- 6-4: Stainless steels -- 6-5: Tool steels -- 6-6: Alloy cast steels and irons -- Case Study: Interior tub of a top-loading washing machine -- Chapter 7: Nonferrous metals and alloys: -- 7-1: Introduction -- 7-2: Copper and copper alloys -- 7-3: Aluminum and aluminum alloys -- 7-4: Magnesium and magnesium alloys -- 7-5: Zinc-based alloys -- 7-6: Titanium and titanium alloys -- 7-7: Nickel-based alloys -- 7-8: Superalloys and other metals designed for high-temperature service -- 7-9: Lead, tin, and their alloys -- 7-10: Some lesser-known metals and alloys -- 7-11: Graphite -- Case Study: Nonsparking wrench -- Chapter 8: Nonmetallic materials: plastics, elastomers, ceramics, and composites: -- 8-1: Introduction -- 8-2: Plastics -- 8-3: Elastomers -- 8-4: Ceramics -- 8-5: Composite materials -- Case Study: Two-wheel dolly handles -- Chapter 9: Material selection: -- 9-1: Introduction -- 9-2: Material selection and manufacturing -- 9-3: Design process -- 9-4: Procedure for material selection -- 9-5: Additional factors to consider -- 9-6: Consideration of the manufacturing process -- 9-7: Ultimate objective -- 9-8: Materials substitution -- 9-9: Effect of product liability on materials selection -- 9-10: Aids to material selection -- Case Study: Material selection -- Inspection: -- Chapter 10: Measurement and inspection: -- 10-1: Introduction -- 10-2: Standards of measurement -- 10-3: Allowance and tolerance -- 10-4: Inspection methods for measurement -- 10-5: Measuring instruments -- 10-6: Vision systems for measurement -- 10-7: Coordinate measuring machines -- 10-8: Angle-measuring instruments -- 10-9: Gages for attributes measuring -- 10-10: Surface roughness measurement -- Case Study: Machining accuracy over the last century.
  • Chapter 11: Nondestructive inspection and testing: -- 11-1: Destructive versus nondestructive testing -- 11-2: Visual inspection -- 11-3: Liquid penetrant inspection -- 11-4: Magnetic particle inspection -- 11-5: Ultrasonic inspection -- 11-6: Radiography -- 11-7: Eddy-current testing -- 11-8: Acoustic emission monitoring -- 11-9: Other methods of nondestructive testing and inspection -- 11-10: Dormant versus critical flaws -- Case Study: Portable failure analysis kit -- Chapter 12: Process capability and quality control: -- 12-1: Introduction -- 12-2: Determining process capability -- 12-3: Inspection and quality control -- 12-4: Determining causes for problems in quality -- 12-5: Summary -- Case Study: Boring QC chart blunders -- Casting Processes: -- Chapter 13: Fundamentals of casting: -- 13-1: Introduction to materials processing -- 13-2: Introduction to casting -- 13-3: Casting terminology -- 13-4: Solidification process -- 13-5: Patterns -- 13-6: Design considerations in castings -- Case Study: Cast oil-field fitting -- Chapter 14: Expendable-mold casting processes: -- 14-1: Introduction -- 14-2: Sand casting -- 14-3: Cores and core making -- 14-4: Other expendable-mold processes with multiple-use patterns -- 14-5: Expendable-mold processes using single-use patterns -- 14-6: Shakeout, cleaning, and finishing -- 14-7: Summary -- Case Study: Moveable and fixed jaw pieces for a heavy-duty bench vise -- Chapter 15: Multiple-use-mold casting processes: -- 15-1: Introduction -- 15-2: Permanent mold casting -- 15-3: Die casting -- 15-4: Squeeze casting and semisolid casting -- 15-5: Centrifugal casting -- 15-6: Semicentrifugal casting -- 15-7: Centrifuging -- 15-8: Continuous casting -- 15-9: Electromagnetic (or levitation) casting -- 15-10: Melting and pouring -- 15-11: Pouring practice -- 15-12: Cleaning, finishing, and heat treating of castings -- 15-13: Robots in foundry operations -- 15-14: Process selection -- Case Study: Baseplate for a household steam iron -- Chapter 16: Powder metallurgy: -- 16-1: Introduction -- 16-2: Basic process -- 16-3: Powder manufacture -- 16-4: Rapidly solidified powder (microcrystalline and amorphous) -- 16-5: Powder testing and evaluation -- 16-6: Powder mixing and blending -- 16-7: Compacting -- 16-8: Sintering -- 16-9: Hot isostatic pressing -- 16-10: Other techniques to produce high-density P/M products -- 16-11: Secondary operations -- 16-12: Properties of P/M products -- 16-13: Design of powder metallurgy parts -- 16-14: Powder metallurgy products -- 16-15: Advantages and disadvantages of powder metallurgy -- 16-16: Process summary -- Case Study: Impeller for an automobile water pump -- Forming Processes.
  • Chapter 17: Fundamentals of metal forming: -- 17-1: Introduction -- 17-2: Forming processes: independent variables -- 17-3: Dependent variables -- 17-4: Independent-dependent relationships -- 17-5: Process modeling -- 17-6: General parameters -- 17-7: Friction and lubrication under metalworking conditions -- 17-8: Temperature concerns -- Case Study: Repairs to a damaged propeller -- Chapter 18: Hot-working processes: -- 18-1: Introduction -- 18-2: Classification of deformation processes -- 18-3: Hot-working processes -- 18-4: Rolling -- 18-5: Forging -- 18-6: Extrusion -- 18-7: Hot drawing of sheet and plate -- 18-8: Pipe welding -- 18-9: Piercing -- Case Study: Outboard motor brackets -- Chapter 19: Cold-working processes: -- 19-1: Introduction -- 19-2: Squeezing processes -- 19-3: Bending -- 19-4: Shearing operations -- 19-5: Drawing and sheet metal forming -- 19-6: Alternative methods of producing sheet-type products -- 19-7: Presses -- Case Study: Diesel engine fuel metering lever -- Chapter 20: Fabrication of plastics, ceramics, and composites: -- 20-1: Introduction -- 20-2: Fabrication of plastics -- 20-3: Processing of rubber and elastomers -- 20-4: Processing of ceramics -- 20-5: Fabrication of composite materials -- Case Study: Fabrication of lavatory wash basins -- Machining Processes: -- Chapter 21: Fundamentals of machining/orthogonal machining: -- 21-1: Introduction -- 21-2: Fundamentals -- 21-3: Energy and power in machining -- 21-4: Orthogonal machining (two force) -- 21-5: Merchant's model -- 21-6: Mechanics of machining (statics) -- 21-7: Shear strain y and shear front angle -- 21-8: Mechanics of machining (dynamics) -- 21-9: Summary -- Chapter 22: Cutting tools for machining: -- 22-1: Introduction -- 22-2: Tool coating processes -- 22-3: Cutting tool materials -- 22-4: Tool geometry -- 22-5: Tool failure and tool life -- 22-6: Flank wear -- 22-7: Economics of machining -- 22-8: Cutting fluids -- Chapter 23: Turning and boring and related processes: -- 23-1: Introduction -- 23-2: Fundamentals of turning, boring, and facing -- 23-3: Lathe design and terminology -- 23-4: Types of boring machines -- 23-5: Cutting tools for lathes -- 23-6: Workholding in lathes -- Case Study: Estimating the machining time for turning.
  • Chapter 24: Drilling and related hole-making processes: -- 24-1: Introduction -- 24-2: Fundamentals of the drilling process -- 24-3: Types of drills -- 24-4: Toolholders for drills -- 24-5: Workholding for drilling -- 24-6: Machine tools for drilling -- 24-7: Cutting fluids for drilling -- 24-8: Counterboring, countersinking, and spot facing -- 24-9: Reaming -- Case Study: Bolt-down leg on a casting -- Chapter 25: Milling: -- 25-1: Introduction -- 25-2: Fundamentals of milling processes -- 25-3: Milling tools and cutters -- 25-4: Machines for milling -- 25-5: Workholding devices for milling -- 25-6: History of the milling machine -- Chapter 26: Shaping, planning, broaching, sawing, and filing: -- 26-1: Introduction to shaping and planning -- 26-2: Introduction to broaching -- 26-3: Fundamentals of broaching -- 26-4: Broaching machines -- 26-5: Introduction to sawing -- 26-6: Saw blades -- 26-7: Types of sawing machines -- 26-8: Introduction to filing -- 26-9: Types of files -- 26-10: Filing machines -- Case Study: Socket with the triangular hole -- Chapter 27: Abrasive machining processes: -- 27-1: Introduction -- 27-2: Abrasives -- 27-3: Grinding wheel structure and grade -- 27-4: Grinding wheel identification -- 27-5: Grinding machines -- 27-6: Design considerations in grinding -- 27-7: Honing -- 27-8: Superfinishing -- 27-9: Lapping -- Case Study: Aluminum retainer rings -- Chapter 28: Nontraditional machining: -- 28-1: Introduction -- 28-2: Chemical machining processes -- 28-3: Electrochemical machining processes -- 28-4: Mechanical NTM processes -- 28-5: Thermal NTM processes -- Chapter 29: Workholding devices: -- 29-1: Introduction -- 29-2: Conventional fixture design -- 29-3: Design steps -- 29-4: Clamping considerations -- 29-5: Chip disposal -- 29-6: Unloading and loading time -- 29-7: Example of jig design -- 29-8: Types of jigs -- 29-9: Conventional fixtures -- 29-10: Modular fixturing -- 29-11: Setup and changeover -- 29-12: Clamps -- 29-13: Other workholding devices -- 29-14: Economic justification of jigs and fixtures -- Case Study: Overhead crane installation -- Chapter 30: Thread and gear manufacturing: -- 30-1: Introduction -- 30-2: Thread making -- 30-3: Internal thread cutting-tapping -- 30-4: Thread milling -- 30-5: Thread grinding -- 30-6: Thread rolling -- 30-7: Gear making -- 30-8: Gear types -- 30-9: Gear manufacturing -- 30-10: Machining of gears -- 30-11: Gear finishing -- 30-12: Gear inspection -- Case Study: Vented cap screws -- Chapter 31: Surface treatments, finishing, and integrity: -- 31-1: Introduction -- 31-2: Mechanical cleaning and finishing -- 31-3: Chemical cleaning -- 31-4: Coatings -- 31-5: Vaporized metal coatings -- 31-6: Clad materials -- 31-7: Textured surfaces -- 31-8: Coil-coated sheets -- 31-9: Edge finishing and burrs -- 31-10: Fatigue failures associated with surface integrity -- Case Study: Burrs on Tonto's collar -- Chapter 32: Manufacturing automation: -- 32-1: Introduction -- 32-2: Numerical control and the A(4) level of automation -- 32-3: Robotics -- 32-4: A(4) versus A(5) level of automation -- 32-5: Computer-integrated manufacturing -- 32-6: Computer-aided design -- 32-7: Basic principles of numerical control -- 32-8: Machining center features and trends -- 32-9: Ultra High-Speed Machining Centers (UHSMCs) -- 32-10: Summary -- Case Study: Steam line holes.
  • Chapter 33: Rapid prototyping and freeform fabrication: -- 33-1: Introduction -- 33-2: Basic concepts in freeform fabrication -- 33-3: Photopolymer-based FF processes -- 33-4: Deposition-based FF processes -- 33-5: Powder-based FF processes -- 33-6: Lamination-based FF processes -- 33-7: Rapid tooling -- 33-8: Economic considerations -- Case Study: Flywheel for a high-speed computer printer -- Chapter 34: Microelectronic manufacturing and electronic assembly: -- 34-1: Introduction -- 34-2: How electronic products are made -- 34-3: Semiconductors -- 34-4: How ICs are made -- 34-5: How the silicon wafer is made -- 34-6: Fabricating IC on silicon wafers -- 34-7: Thin film deposition -- 34-8: IC Packaging -- 34-9: Printed circuit boards -- 34-10: Electronic assembly -- Joining Processes: -- Chapter 35: Fundamentals of joining: -- 35-1: Introduction to welding processes -- 35-2: Classification of welding and thermal cutting processes -- 35-3: Welding basics and common concerns -- 35-4: Types of fusion welds and types of joints -- 35-5: Design considerations -- 35-6: Heat effects -- 35-7: Weldability or joinability -- 35-8: Summary -- Chapter 36: Gas flame processes: -- 36-1: Oxyfuel gas welding -- 36-2: Oxygen torch cutting -- 36-3: Flame straightening -- Chapter 37: Arc processes: -- 37-1: Arc welding -- 37-2: Consumable electrode arc welding -- 37-3: Nonconsumable electrode arc welding -- 37-4: Welding equipment -- 37-5: Arc cutting -- 37-6: Metallurgical and heat effects in thermal cutting -- Case Study: Bicycle frame repair -- Chapter 38: Resistance welding and other welding processes: -- 38-1: Introduction -- 38-2: Theory of resistance welding -- 38-3: Resistance welding processes -- 38-4: Advantages and limitations of resistance welding -- 38-5: Solid-state welding processes -- 38-6: Other welding and cutting processes -- 38-7: Welding of plastics -- 38-8: Welding-related processes -- Case Study: Field repair to a power transformer case -- Chapter 39: Brazing and soldering: -- 39-1: Introduction -- 39-2: Brazing -- 39-3: Soldering -- Chapter 40: Adhesive bonding and mechanical fastening: -- 40-1: Adhesive bonding -- 40-2: Mechanical fastening -- Case Study: Golf club heads with insert -- Manufacturing Systems Design: -- Chapter 41: Manufacturing and production systems: -- 41-1: Introduction -- 41-2: Production system (the enterprise) -- 41-3: Manufacturing systems -- 41-4: Classification of manufacturing systems -- 41-5: Evolution of the first factory -- 41-6: Evolution of the second MSD-the flow shop -- 41-7: Third MSD-the lean shop -- 41-8: Enterprise -- 41-9: Typical functional areas -- Case Study: Fire extinguisher pressure gage -- Chapter 42: System and cell design: -- 42-1: Introduction -- 42-2: Enterprise (production) system design -- 42-3: Linked-cell manufacturing system (L-CMS) -- 42-4: Manufacturing cell design -- 42-5: Summary -- Case Study: Snowmobile accident -- Chapter 43: Implementation of lean manufacturing systems and cells: -- 43-1: New integrated manufacturing system design -- 43-2: Management philosophy must change -- 43-3: Lean production methodology for implementation -- 43-4: Interim cells using new machine tools -- 43-5: Lean manufacturing cell design -- 43-6: Robotic manufacturing cells -- 43-7: Ergonomics of lean manufacturing cells -- 43-8: Why lean manufacturing programs fail -- 43-9: Summary: Use IM, C not CIM -- Case Study: Automobile water pump impeller -- Selected references for additional study -- Index.
Other names
Genre
  • Bibliography
  • Illustrated
  • text
Language
  • English
Internet Resources

Summary

  • From the back cover: Understand the fundamentals of manufacturing, from raw materials to finished products. Often emulated but never matched, DeGarmo's Materials and Processes in Manufacturing has been the standard introduction to manufacturing fundamentals since 1957. The book has long been noted for its comprehensive coverage of the basic workings of various materials and processes. In the Ninth Edition, co-authors Ron Kohser and J T. Black have added material on new processes, manufacturing systems design, and quality control. New and updated examples, problems, and lab exercises have also been added. New to this edition: Study new process: while the book still focuses on casing, forming, machining, and joining, new material on rapid prototyping, electronics, and metal-cutting has been added. See the big picture: redesigning the factory. This edition includes more coverage of lean manufacturing and manufacturing systems design, as well as in-depth material on quality control and process capability, to help you understand the system as a whole. Understand machinability factors. The Ninth Edition features a new section in Chapter 21 on machining dynamics. This is the only text that explains how machinability factors are determined and how the values for speed, feed, and depth of cut are rationalized. Learn and practice online. New interactive problems, case studies, and lab exercises are available on the book's web site, at www.wiley.com/college/degarmo. Features: Understand manufacturing fundamentals. The authors cover the properties and behaviors of a range of materials and the basics of various manufacturing processes, so you get a clear introduction to a variety of options. Get familiar with the language and the equipment of real factories. The authors introduce you to the technical terms used on the factory floor, and numerous photos and illustrations help you understand how equipment works.

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University of Portsmouth: University Library, First Floor 671 Standard
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