Machine generated contents note: I.1.What is Manufacturing? -- I.2.Product Design and Concurrent Engineering -- I.3.Design for Manufacture, Assembly, Disassembly, and Service -- I.4.Green Design and Manufacturing -- I.5.Selection of Materials -- I.6.Selection of Manufacturing Processes -- I.7.Computer-integrated Manufacturing -- I.8.Quality Assurance and Total Quality Management -- I.9.Lean Production and Agile Manufacturing -- I.10.Manufacturing Costs and Global Competition -- I.11.Trends in Manufacturing -- pt. I Fundamentals of Materials: Behavior and Manufacturing Properties -- 1.The Structure of Metals -- 1.1.Introduction -- 1.2.Types of Atomic Bonds -- 1.3.The Crystal Structure of Metals -- 1.4.Deformation and Strength of Single Crystals -- 1.5.Grains and Grain Boundaries -- 1.6.Plastic Deformation of Polycrystalline Metals -- 1.7.Recovery, Recrystallization, and Grain Growth -- 1.8.Cold, Warm, and Hot Working -- Summary -- Key Terms -- Bibliography -- Review Questions -- Qualitative Problems -- Quantitative Problems -- Synthesis, Design, and Projects -- 2.Mechanical Behavior, Testing, and Manufacturing Properties of Materials -- 2.1.Introduction -- 2.2.Tension -- 2.3.Compression -- 2.4.Torsion -- 2.5.Bending (Flexure) -- 2.6.Hardness -- 2.7.Fatigue -- 2.8.Creep -- 2.9.Impact -- 2.10.Failure and Fracture of Materials -- 2.11.Residual Stresses -- 2.12.Work, Heat, and Temperature -- Summary -- Key Terms -- Bibliography -- Review Questions -- Qualitative Problems -- Quantitative Problems -- Synthesis, Design, and Projects -- 3.Physical Properties of Materials -- 3.1.Introduction -- 3.2.Density -- 3.3.Melting Point -- 3.4.Specific Heat -- 3.5.Thermal Conductivity -- 3.6.Thermal Expansion -- 3.7.Electrical, Magnetic, and Optical Properties -- 3.8.Corrosion Resistance -- Summary -- Key Terms -- Bibliography -- Review Questions -- Qualitative Problems -- Quantitative Problems -- Synthesis, Design, and Projects -- 4.Metal Alloys: Their Structure and Strengthening by Heat Treatment -- 4.1.Introduction -- 4.2.Structure of Alloys -- 4.3.Phase Diagrams -- 4.4.The Iron-carbon System -- 4.5.The Iron-iron-carbide Phase Diagram and the Development of Microstructures in Steels -- 4.6.Cast Irons -- 4.7.Heat Treatment of Ferrous Alloys -- 4.8.Hardenability of Ferrous Alloys -- 4.9.Heat Treatment of Nonferrous Alloys and Stainless Steels -- 4.10.Case Hardening -- 4.11.Annealing -- 4.12.Heat-treating Furnaces and Equipment -- 4.13.Design Considerations for Heat Treating -- Summary -- Key Terms -- Bibliography -- Review Questions -- Qualitative Problems -- Quantitative Problems -- Synthesis, Design, and Projects -- 5.Ferrous Metals and Alloys: Production, General Properties, and Applications -- 5.1.Introduction -- 5.2.Production of Iron and Steel -- 5.3.Casting of Ingots -- 5.4.Continuous Casting -- 5.5.Carbon and Alloy Steels -- 5.6.Stainless Steels -- 5.7.Tool and Die Steels -- Summary -- Key Terms -- Bibliography -- Review Questions -- Qualitative Problems -- Quantitative Problems -- Synthesis, Design, and Projects -- 6.Nonferrous Metals and Alloys: Production, General Properties, and Applications -- 6.1.Introduction -- 6.2.Aluminum and Aluminum Alloys -- 6.3.Magnesium and Magnesium Alloys -- 6.4.Copper and Copper Alloys -- 6.5.Nickel and Nickel Alloys -- 6.6.Superalloys -- 6.7.Titanium-and Titanium Alloys -- 6.8.Refractory Metals and Alloys -- 6.9.Beryllium -- 6.10.Zirconium -- 6.11.Low-melting Alloys -- 6.12.Precious Metals -- 6.13.Shape-memory Alloys (Smart Materials) -- 6.14.Amorphous Alloys (Metallic Glasses) -- 6.15.Metal Foams -- Summary -- Key Terms -- Bibliography -- Review Questions -- Qualitative Problems -- Quantitative Problems -- Synthesis, Design, and Projects -- 7.Polymers: Structure, General Properties, and Applications -- 7.1.Introduction -- 7.2.The Structure of Polymers -- 7.3.Thermoplastics -- 7.4.Thermosetting Plastics -- 7.5.Additives in Plastics -- 7.6.General Properties and Applications of Thermoplastics -- 7.7.General Properties and Applications of Thermosetting Plastics -- 7.8.Biodegradable Plastics -- 7.9.Elastomers (Rubbers) -- Summary -- Key Terms -- Bibliography -- Review Questions -- Qualitative Problems -- Quantitative Problems -- Synthesis, Design, and Projects -- 8.Ceramics, Glass, Graphite, Diamond, and Nanomaterials: Structure, General Properties, and Applications -- 8.1.Introduction -- 8.2.The Structure of Ceramics -- 8.3.General Properties and Applications of Ceramics -- 8.4.Glasses -- 8.5.Glass Ceramics -- 8.6.Graphite -- 8.7.Diamond -- 8.8.Nanomaterials -- Summary -- Key Terms -- Bibliography -- Review Questions -- Qualitative Problems -- Quantitative Problems -- Synthesis, Design, and Projects -- 9.Composite Materials: Structure, General Properties, and Applications -- 9.1.Introduction -- 9.2.The Structure of Reinforced Plastics -- 9.3.Properties of Reinforced Plastics -- 9.4.Applications of Reinforced Plastics -- 9.5.Metal-matrix Composites -- 9.6.Ceramic-matrix Composites -- 9.7.Other Composites -- Summary -- Key Terms -- Bibliography -- Review Questions -- Qualitative Problems -- Quantitative Problems -- Synthesis, Design, and Projects -- pt. II Metal-casting Processes and Equipment -- 10.Fundamentals of Metal Casting -- 10.1.Introduction -- 10.2.Solidification of Metals -- 10.3.Fluid Flow -- 10.4.Fluidity of Molten Metal -- 10.5.Heat Transfer -- 10.6.Defects -- Summary -- Key Terms -- Bibliography -- Review Questions -- Qualitative Problems -- Quantitative Problems -- Synthesis, Design, and Projects -- 11.Metal-casting Processes and Equipment -- 11.1.Introduction -- 11.2.Expendable-mold, Permanent-pattern Casting Processes -- 11.3.Expendable-mold, Expendable-pattern Casting Processes -- 11.4.Permanent-mold Casting Processes -- 11.5.Casting Techniques for Single-crystal Components -- 11.6.Rapid Solidification -- 11.7.Inspection of Castings -- 11.8.Melting Practice and Furnaces -- 11.9.Foundries and Foundry Automation -- Summary -- Key Terms -- Bibliography -- Review Questions -- Qualitative Problems -- Quantitative Problems -- Synthesis, Design, and Projects -- 12.Metal Casting: Design, Materials, and Economics -- 12.1.Introduction -- 12.2.Design Considerations in Casting -- 12.3.Casting Alloys -- 12.4.Economics of Casting -- Summary -- Key Terms -- Bibliography -- Review Questions -- Qualitative Problems -- Quantitative Problems -- Synthesis, Design, and Projects -- pt.

Note continued: 19.15.Design Considerations -- 19.16.Economics of Processing Plastics and Composite Materials -- Summary -- Key Terms -- Bibliography -- Review Questions -- Qualitative Problems -- Quantitative Problems -- Synthesis, Design, and Projects -- 20.Rapid-prototyping Processes and Operations -- 20.1.Introduction -- 20.2.Subtractive Processes -- 20.3.Additive Processes -- 20.4.Virtual Prototyping -- 20.5.Self-replicating Machines -- 20.6.Direct Manufacturing and Rapid Tooling -- Summary -- Key Terms -- Bibliography -- Review Questions -- Qualitative Problems -- Quantitative Problems -- Synthesis, Design, and Projects -- pt. IV Machining Processes and Machine Tools -- 21.Fundamentals of Machining -- 21.1.Introduction -- 21.2.Mechanics of Cutting -- 21.3.Cutting Forces and Power -- 21.4.Temperatures in Cutting -- 21.5.Tool Life: Wear and Failure -- 21.6.Surface Finish and Integrity -- 21.7.Machinability -- Summary -- Key Terms -- Bibliography -- Review Questions -- Qualitative Problems -- Quantitative Problems -- Synthesis, Design, and Projects -- 22.Cutting-tool Materials and Cutting Fluids -- 22.1.Introduction -- 22.2.High-speed Steels -- 22.3.Cast-cobalt Alloys -- 22.4.Carbides -- 22.5.Coated Tools -- 22.6.Alumina-based Ceramics -- 22.7.Cubic Boron Nitride -- 22.8.Silicon-nitride-based Ceramics -- 22.9.Diamond -- 22.10.Whisker-reinforced Materials and Nanomaterials -- 22.11.Tool Costs and Reconditioning of Tools -- 22.12.Cutting Fluids -- Summary -- Key Terms -- Bibliography -- Review Questions -- Qualitative Problems -- Quantitative Problems -- Synthesis, Design, and Projects -- 23.Machining Processes: Turning and Hole Making -- 23.1.Introduction -- 23.2.The Turning Process -- 23.3.Lathes and Lathe Operations -- 23.4.Boring and Boring Machines -- 23.5.Drilling, Drills, and Drilling Machines -- 23.6.Reaming and Reamers -- 23.7.Tapping and Taps -- Summary -- Key Terms -- Bibliography -- Review Questions -- Qualitative Problems -- Quantitative Problems -- Synthesis, Design, and Projects -- 24.Machining Processes: Milling, Broaching, Sawing, Filing, and Gear Manufacturing -- 24.1.Introduction -- 24.2.Milling and Milling Machines -- 24.3.Planing and Shaping -- 24.4.Broaching and Broaching Machines -- 24.5.Sawing -- 24.6.Filing -- 24.7.Gear Manufacturing by Machining -- Summary -- Key Terms -- Bibliography -- Review Questions -- Qualitative Problems -- Quantitative Problems -- Synthesis, Design, and Projects -- 25.Machining Centers, Machine-tool Structures, and Machining Economics -- 25.1.Introduction -- 25.2.Machining Centers -- 25.3.Machine-tool Structures -- 25.4.Vibration and Chatter in Machining Operations -- 25.5.High-speed Machining -- 25.6.Hard Machining -- 25.7.Ultraprecision Machining -- 25.8.Machining Economics -- Summary -- Key Terms -- Bibliography -- Review Questions -- Qualitative Problems -- Quantitative Problems -- Synthesis, Design, and Projects -- 26.Abrasive Machining and Finishing Operations -- 26.1.Introduction -- 26.2.Abrasives and Bonded Abrasives -- 26.3.The Grinding Process -- 26.4.Grinding Operations and Machines -- 26.5.Design Considerations for Grinding -- 26.6.Ultrasonic Machining -- 26.7.Finishing Operations -- 26.8.Deburring Operations -- 26.9.Economics of Abrasive Machining and Finishing Operations -- Summary -- Key Terms -- Bibliography -- Review Questions -- Qualitative Problems -- Quantitative Problems -- Synthesis, Design, and Projects -- 27.Advanced Machining Processes and Equipment -- 27.1.Introduction -- 27.2.Chemical Machining -- 27.3.Electrochemical Machining -- 27.4.Electrochemical Grinding -- 27.5.Electrical-discharge Machining -- 27.6.Laser-beam Machining -- 27.7.Electron-beam Machining -- 27.8.Water-jet Machining -- 27.9.Abrasive-jet Machining -- 27.10.Hybrid Machining Systems -- 27.11.Economics of Advanced Machining Processes -- Summary -- Key Terms -- Bibliography -- Review Questions -- Qualitative Problems -- Quantitative Problems -- Synthesis, Design, and Projects -- pt.

III Forming and Shaping Processes and Equipment -- 13.Metal-rolling Processes and Equipment -- 13.1.Introduction -- 13.2.The Flat-rolling Process -- 13.3.Flat-rolling Practice -- 13.4.Rolling Mills -- 13.5.Various Rolling Processes and Mills -- Summary -- Key Terms -- Bibliography -- Review Questions -- Qualitative Problems -- Quantitative Problems -- Synthesis, Design, and Projects -- 14.Metal-forging Processes and Equipment -- 14.1.Introduction -- 14.2.Open-die Forging -- 14.3.Impression-die and Closed-die Forging -- 14.4.Various Forging Operations -- 14.5.Forgeability of Metals; Forging Defects -- 14.6.Die Design, Die Materials, and Lubrication -- 14.7.Die-manufacturing Methods and Die Failure -- 14.8.Forging Machines -- 14.9.Economics of Forging -- Summary -- Key Terms -- Bibliography -- Review Questions -- Qualitative Problems -- Quantitative Problems -- Synthesis, Design, and Projects -- 15.Metal Extrusion and Drawing Processes and Equipment -- 15.1.Introduction -- 15.2.The Extrusion Process -- 15.3.Hot Extrusion -- 15.4.Cold Extrusion -- 15.5.Extrusion Defects -- 15.6.Design Considerations -- 15.7.Extrusion Equipment -- 15.8.The Drawing Process -- 15.9.Drawing Practice -- 15.10.Drawing Defects and Residual Stresses -- 15.11.Drawing Equipment -- Summary -- Key Terms -- Bibliography -- Review Questions -- Qualitative Problems -- Quantitative Problems -- Synthesis, Design, and Projects -- 16.Sheet-metal Forming Processes and Equipment -- 16.1.Introduction -- 16.2.Shearing -- 16.3.Sheet-metal Characteristics and Formability -- 16.4.Formability Tests for Sheet Metals -- 16.5.Bending Sheets, Plates, and Tubes -- 16.6.Miscellaneous Bending and Related Forming Operations -- 16.7.Deep Drawing -- 16.8.Rubber Forming and Hydroforming -- 16.9.Spinning -- 16.10.Superplastic Forming -- 16.11.Hot Stamping -- 16.12.Specialized Forming Processes -- 16.13.Manufacturing of Metal Honeycomb Structures -- 16.14.Design Considerations in Sheet-metal Forming -- 16.15.Equipment for Sheet-metal Forming -- 16.16.Economics of Sheet-forming Operations -- Summary -- Key Terms -- Bibliography -- Review Questions -- Qualitative Problems -- Quantitative Problems -- Synthesis, Design, and Projects -- 17.Powder Metal Processes and Equipment -- 17.1.Introduction -- 17.2.Production of Metal Powders -- 17.3.Compaction of Metal Powders -- 17.4.Sintering -- 17.5.Secondary and Finishing Operations -- 17.6.Design Considerations -- 17.7.Economics of Powder Metallurgy -- Summary -- Key Terms -- Bibliography -- Review Questions -- Qualitative Problems -- Quantitative Problems -- Synthesis, Design, and Projects -- 18.Ceramics, Glasses, and Superconductors: Processing and Equipment -- 18.1.Introduction -- 18.2.Shaping Ceramics -- 18.3.Forming and Shaping of Glass -- 18.4.Techniques for Strengthening and Annealing Glass -- 18.5.Design Considerations for Ceramics and Glasses -- 18.6.Processing of Superconductors -- Summary -- Key Terms -- Bibliography -- Review Questions -- Qualitative Problems -- Quantitative Problems -- Synthesis, Design, and Projects -- 19.Plastics and Composite Materials: Forming and Shaping -- 19.1.Introduction -- 19.2.Extrusion -- 19.3.Injection Molding -- 19.4.Blow Molding -- 19.5.Rotational Molding -- 19.6.Thermoforming -- 19.7.Compression Molding -- 19.8.Transfer Molding -- 19.9.Casting -- 19.10.Foam Molding -- 19.11.Cold Forming and Solid-phase Forming -- 19.12.Processing Elastomers -- 19.13.Processing Polymer-matrix Composites -- 19.14.Processing Metal-matrix and Ceramic-matrix Composites --

V Micromanufacturing and Fabrication of Microelectronic Devices -- 28.Fabrication of Microelectronic Devices -- 28.1.Introduction -- 28.2.Clean Rooms -- 28.3.Semiconductors and Silicon -- 28.4.Crystal-Growing and Water Preparation -- 28.5.Film Deposition -- 28.6.Oxidation -- 28.7.Lithography -- 28.8.Etching -- 28.9.Diffusion and Ion Implantation -- 28.10.Metallization and Testing -- 28.11.Wire Bonding and Packaging -- 28.12.Yield and Reliability -- 28.13.Printed Circuit Boards -- Summary -- Key Terms -- Bibliography -- Review Questions -- Qualitative Problems -- Quantitative Problems -- Synthesis, Design, and Projects -- 29.Fabrication of Microelectromechanical Devices and Systems; Nanoscale Manufacturing -- 29.1.Introduction -- 29.2.Micromachining of MEMS Devices -- 29.3.Electroforming-based Processes -- 29.4.Solid Free-form Fabrication of Devices -- 29.5.Nanoscale Manufacturing -- Summary -- Key Terms -- Bibliography -- Review Questions -- Qualitative Problems -- Quantitative Problems -- Synthesis, Design, and Projects -- pt. VI Joining Processes and Equipment -- 30.Fusion-welding Processes -- 30.1.Introduction -- 30.2.Oxyfuel-gas Welding -- 30.3.Arc-welding Processes: Nonconsumable Electrode -- 30.4.Arc-welding Processes: Consumable Electrode -- 30.5.Electrodes for Arc Welding -- 30.6.Electron-beam Welding -- 30.7.Laser-beam Welding -- 30.8.Cutting -- 30.9.The Weld Joint, Weld Quality, and Testing -- 30.10.Joint Design and Process Selection -- Summary -- Key Terms -- Bibliography -- Review Questions -- Qualitative Problems -- Quantitative Problems -- Synthesis, Design, and Projects -- 31.Solid-State Welding Processes -- 31.1.Introduction -- 31.2.Cold Welding and Roll Bonding -- 31.3.Ultrasonic Welding -- 31.4.Friction Welding -- 31.5.Resistance Welding -- 31.6.Explosion Welding -- 31.7.Diffusion Bonding -- 31.8.Economics of Welding Operations -- Summary -- Key Terms -- Bibliography -- Review Questions -- Qualitative Problems -- Quantitative Problems -- Synthesis, Design, and Projects -- 32.Brazing, Soldering, Adhesive-bonding, and Mechanical Fastening Processes -- 32.1.Introduction -- 32.2.Brazing -- 32.3.Soldering -- 32.4.Adhesive-bonding -- 32.5.Mechanical Fastening -- 32.6.Joining Plastics, Ceramics, and Glasses -- 32.7.Economics of Joining Operations -- Summary -- Key Terms -- Bibliography -- Review Questions -- Qualitative Problems -- Quantitative Problems -- Synthesis, Design, and Projects -- pt. VII Surface Technology -- 33.Surface Roughness and Measurement; Friction, Wear, and Lubrication -- 33.1.Introduction -- 33.2.Surface Structure and Integrity -- 33.3.Surface Texture and Roughness -- 33.4.Friction -- 33.5.Wear -- 33.6.Lubrication -- 33.7.Metalworking Fluids and Their Selection -- Summary -- Key Terms -- Bibliography -- Review Questions -- Qualitative Problems -- Quantitative Problems -- Synthesis, Design, and Projects -- 34.Surface Treatments, Coatings, and Cleaning -- 34.1.Introduction -- 34.2.Mechanical Surface Treatments -- 34.3.Mechanical Plating and Cladding -- 34.4.Case Hardening and Hard Facing -- 34.5.Thermal Spraying -- 34.6.Vapor Deposition -- 34.7.Ion Implantation and Diffusion Coating -- 34.8.Laser Treatments -- 34.9.Electroplating, Electroless Plating, and Electroforming -- 34.10.Conversion Coatings -- 34.11.Hot Dipping -- 34.12.Porcelain Enameling; Ceramic and Organic Coatings -- 34.13.Diamond Coating and Diamond-like Carbon -- 34.14.Surface Texturing -- 34.15.Painting -- 34.16.Cleaning of Surfaces -- Summary -- Key Terms -- Bibliography -- Review Questions -- Qualitative Problems -- Quantitative Problems -- Synthesis, Design, and Projects -- pt.

VIII Engineering Metrology, Instrumentation, and Quality Assurance -- 35.Engineering Metrology and Instrumentation -- 35.1.Introduction -- 35.2.Measurement Standards -- 35.3.Geometric Features of Parts: Analog and Digital Measurements -- 35.4.Traditional Measuring Methods and Instruments -- 35.5.Modern Measuring Instruments and Machines -- 35.6.Automated Measurement -- 35.7.General Characteristics and Selection of Measuring Instruments -- 35.8.Geometric Dimensioning and Tolerancing -- Summary -- Key Terms -- Bibliography -- Review Questions -- Qualitative Problems -- Quantitative Problems -- Synthesis, Design, and Projects -- 36.Quality Assurance, Testing, and Inspection -- 36.1.Introduction -- 36.2.Product Quality -- 36.3.Quality Assurance -- 36.4.Total Quality Management -- 36.5.Taguchi Methods -- 36.6.The ISO and QS Standards -- 36.7.Statistical Methods of Quality Control -- 36.8.Statistical Process Control -- 36.9.Reliability of Products and Processes -- 36.10.Nondestructive Testing -- 36.11.Destructive Testing -- 36.12.Automated Inspection -- Summary -- Key Terms -- Bibliography -- Review Questions -- Qualitative Problems -- Quantitative Problems -- Synthesis, Design, and Projects -- pt. IX Manufacturing in a Competitive Environment -- 37.Automation of Manufacturing Processes and Operations -- 37.1.Introduction -- 37.2.Automation -- 37.3.Numerical Control -- 37.4.Adaptive Control -- 37.5.Material Handling and Movement -- 37.6.Industrial Robots -- 37.7.Sensor Technology -- 37.8.Flexible Fixturing -- 37.9.Assembly Systems -- 37.10.Design Considerations for Fixturing, Assembly, Disassembly, and Servicing -- 37.11.Economic Considerations -- Summary -- Key Terms -- Bibliography -- Review Questions -- Qualitative Problems -- Quantitative Problems -- Synthesis, Design, and Projects -- 38.Computer-aided Manufacturing -- 38.1.Introduction -- 38.2.Manufacturing Systems -- 38.3.Computer-integrated Manufacturing -- 38.4.Computer-aided Design and Engineering -- 38.5.Computer-aided Manufacturing -- 38.6.Computer-aided Process Planning -- 38.7.Computer Simulation of Manufacturing Processes and Systems -- 38.8.Group Technology -- Summary -- Key Terms -- Bibliography -- Review Questions -- Qualitative Problems -- Synthesis, Design, and Projects -- 39.Computer-integrated Manufacturing Systems --

Note continued: 39.1.Introduction -- 39.2.Cellular Manufacturing -- 39.3.Flexible Manufacturing Systems -- 39.4.Holonic Manufacturing -- 39.5.Just-in-time Production -- 39.6.Lean Manufacturing -- 39.7.Communications Networks in Manufacturing -- 39.8.Artificial Intelligence -- 39.9.Economic Considerations -- Summary -- Key Terms -- Bibliography -- Review Questions -- Qualitative Problems -- Synthesis, Design, and Projects -- 40.Product Design and Manufacturing in a Competitive Environment -- 40.1.Introduction -- 40.2.Product Design -- 40.3.Product Quality -- 40.4.Life-cycle Assessment and Sustainable Manufacturing -- 40.5.Energy Consumption in Manufacturing -- 40.6.Material Selection for Products -- 40.7.Material Substitution -- 40.8.Manufacturing Process Capabilities -- 40.9.Process Selection -- 40.10.Manufacturing Costs and Cost Reduction -- Summary -- Key Terms -- Bibliography -- Review Questions -- Qualitative Problems -- Synthesis, Design, and Projects.