Manufacturing Engineering and Technology 6th Edition Serope Kalpakjian Stephen Schmid.pdf PDF

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MANUFACTURING ENGINEERING AND TECHNOLOGY SIXTH EDITION IN SI UNITS Serope Kalpakjian Illinois Institute of Technology Steven R. Schmid The University of Notre Dame SI Conversion by Hamldon Musa Universiti Teknologi Malaysia Prentice Hall Singapore London New York Toronto Sydney Tokyo Madrid Mexico ...

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DeGarmo's Mat erials and Processes in Manufact uring 11t h E2d Fayaz Zaman Sect ion 13 Manufact uring Processes ogeel ahmed Solut ions Manual t o Accompany MAT ERIALS AND PROCESS IN MANUFACT URING Nint h Edit ion Deepak Sagar

MANUFACTURING ENGINEERING

AND TECHNOLOGY SIXTH EDITION IN SI UNITS

Serope Kalpakjian Illinois Institute of Technology

Steven R. Schmid The University

of Notre Dame SI Conversion by

Hamldon Musa Universiti Teknologi Malaysia

Prentice Hall Singapore London New York Toronto Sydney Tokyo Madrid Mexico City Munich Paris Capetown Hong Kong Montreal

xiv

lt gives us great pleasure to acknowledge the assistance of the following colleagues in the preparation and publication of this edition of the book: Komel F. Ehmann, Northwestern University; Klaus J .Weinmann, University of California at Berkeley; Timotius Pasang, AUT University; Miguel Sellés Canto, Escola Politecnica Superior d’Alcoi, Universitat Politécnica de Valencia, Spain; and Kevin Wilson, Michael Giordano and Megan McGann, University of Notre Dame.We also acknowledge Kent M. Kalpakjian as the original author ofthe chapter on Fabrication of Microelectronic Devices. We would like to thank our editor, Holly Stark, at Prentice Hall for her enthusiastic support and guidance; and Clare Romeo, Production Editor, for her meticulous editorial and production supervision. We would also like to acknowledge the help of the following in the production of this edition of the book: Greg Dulles, A/V Project Manager; Daniel Sandin, Media Editor; William Opaluch, Editorial Assistant; and Kenny Beck, Cover Design. We are happy to present below a cumulative list of all those individuals who generously have made numerous contributions to various editions of our two

books. B.J. Aaronson

S.

Abella D. Adams K. Anderson S. Arellano D.D. Arola R.A. Arlt V. Aronov A. Bagchi E.D. Baker J. Barak J. Ben-Ari G.F. Benedict S. Bhattacharyya JT. Black W. Blanchard C. Blathras G. Boothroyd D. Bourell B. Bozak N.N. Breyer C.A. Brown R.G. Bruce J Cesarone T.-C. Chang R.L. Cheaney A. Cheda

S.

R.

Chelikani Chen

S.-W. Choi A. Cinar

R.O. Colantonio P. Cotnoir P.J. Courtney P. Demers D. Descoteaux M.F. DeVries R.C. Dix M. Dollar D.A. Domfeld H.I. Douglas M. Dugger D.R. Durham D. Duvall S.A. Dynan J. El Gomayel M.G. Elliott N.X. Fang E.C. Feldy J. Field G.W. Fischer D.A. Fowley R.L. French B.R. Fruchter

D. Furrer R.

Giese

E. Goode

K.L. Graham P. Grigg M. Grujicic P.J. Guichelaar B.

Harriger

D. Harry

M. Hawkins R.J. Hocken E.M. Honig, Jr. Y. Huang S. Imam R.

Jaeger

C. Johnson

K. Jones D. Kalisz

K.M. Kalpakjian J. Kamman S.G. Kapoor R. Kassing R.L. Kegg W.J. Kennedy R. Kerr T. Kesavadas B.D. King

J.E. Kopf R.J. Koronkowski

Kotowski S. Krishnamachari K.M. Kulkami T. Lach L. Langseth M. Laurent M. Levine J

C. Nair

L. Soisson

P.G. Nash

Stewart Stocker L. Strom A.B. Strong K. Subramanian T. Sweeney W.G. Switalski T. Taglialavore M. Tarabishy K.S. Taraman R. Taylor B.S. Thakkar A. Trager A. Tseng C. Tszang M. Tuttle S. Vaze J. Vigneau G.A. Volk G. Wallace J.F. Wang K.J. Weinmann R. Wertheim K. West J. Widmoyer K.R. Williams G. Williamson B. Wiltjer J. Wingfield P.K. Wright N. Zabaras

Nazemetz E.M. Odom J

N. Pacelli U. Pal S.

Paolucci

S.J. Parelukar

B.S. Levy

T. Pasang Z.J. Pei

J. Lewandowski

J

X.Z. Li Z. Liang B.W. Lilly

C. Petronis

A. Lozier

J.M. Prince D.W. Radford W.J. Riffe R.J. Rogalla Y. Rong A.A. Runyan P. Saha G.S. Saletta M. Salimian M. Savic W.J. Schoech S.A. Schwartz M. Selles S. Shepel R. Shivpuri M.T. Siniawski J.E. Smallwood J .P. Sobczak

D.A. Lucca M. Madou S. Mantell L. Mapa A. Marsan R.J. Mattice C. Maziar

T. McClelland W. McClurg L. McGuire

K.E. McKee K.P. Meade M.H. Miller R.

Miller

T.S. Milo D.J. Morrison S.

Mostovoy

Penaluna

M. Philpott M. Pradheeradhi

P.

J

We are also grateful to numerous organizations. companies, and individuals who supplied us with many ofthe illustrations and case studies. These contributions have been specifically acknowledged throughout the text. It is with joy that we gratefully dedicate this book to Professor John A. Schey, our esteemed colleague and distinguished researcher and author, who has been a wise and great teacher, not only to generations of students but to his many colleagues as well. He and his wife, Gitta, have been treasured friends for

many years.

SEROPE KALPAKJIAN STEVEN R. SC HMID JANUARY 2009

xvi

About the Author Serope Kalpakjian is a professor emeritus of mechanical and materials engineering at the Illinois Institute of Technology, Chicago. He is the author of Mechanical Processing of Materials (Van Nostrand, 1967) and co-author of Lubricants and Lubrication in Metalworking Operations (with E.S. Nachtman, Dekker, 1985). Both of the first editions of his books Manufacturing Processes for Engineering Materials (Addison-Wesley, 1984) and Manufacturing Engineering and Technology (Addison Wesley, 1989) have received the M. Eugene Merchant Manufacturing Textbook Award of SME. He has conducted research in several areas in manufacturing processes, is the author of numerous technical papers and articles in professional journals, handbooks, and encyclopedias, and has edited several conference proceedings. He also has been editor and co-editor of various technical journals and has served on the editorial board of Encyclopedia Americana. Professor Kalpakjian has received the Forging Industry Educational and Research Foundation Best Paper Award (1966); the Excellence in Teaching Award from the Illinois Institute of Technology (1970); the ASME Centennial Medallion (1980); the SME International Education Award (1989); a Person of the Millennium Award from IIT (1999); the Albert Easton White Outstanding Teacher Award from ASM International (2000); and the SME Outstanding Young Manufacturing Engineer Award for 2002 was named after him. Professor Kalpakjian is a Life Fellow of ASME; Fellow of SME; Fellow and Life Member of ASM International; Fellow Emeritus of The International Academy for Production Engineering (CIRP); and is a past president and founding member of the North American Manufacturing Research Institution/ SME. He is a high-honors graduate of Robert College (Istanbul), Harvard University, and the Massachusetts Institute of Technology.

XVII

About the Author Steven R. Schmid is an Associate Professor in the Department of Aerospace and Mechanical Engineering at the University of Notre Dame, where he teaches and conducts research in the general areas of manufacturing, machine design, and tribology. He received his Bachelor’s degree in Mechanical Engineering from the Illinois Institute of Technology (with Honors) and Master’s and Ph.D. degrees, both in Mechanical Engineering, from Northwestern University. He has received numerous awards, including the John T. Parsons Award from SME (2000); the Newkirk Award from ASME (2000); the Kaneb Center Teaching Award (2000 and 2003); and the Ruth and Joel Spira Award for Excellence in Teaching (2005). He is also the recipient of a National Science Foundation CAREERS Award (1996) and an ALCOA Foundation Award (1994).

Professor Schmid is the author of almost l00 technical papers, has coauthored the texts Fundamentals of Machine Elements (McGraw-Hill), Fundamentals of Fluid Film Lubrication (Dekker), Manufacturing Processes for Engineering Materials (Prentice Hall), and has contributed two chapters to the CRC Handbook of Modern Tribology. He is an Associate Editor of the ASME Journal of Manufacturing Science and Engineering, and is a registered Professional Engineer and a Certified Manufacturing Engineer of SME.

About the Adaptor Hamidon Musa is Associate Professor with the Manufacturing Division in the Faculty of Mechanical Engineering at Universiti Teknologi Malaysia. He graduated from the University of Birmingham in 1980 and did his postgraduate studies at Cranfield Institute of Technology, UK. His main area of interest is non-traditional machining.

Contents General Introduction 1.1 1.2 1.3

1.4 1.5

1.6 1.7 1.8

1.9

1.10 1.11

1

What 1s Manufacturing? 1 Product Design and Concurrent Engineering 8 Design for Manufacture, Assembly, Disassembly, and Service Green Design and Manufacturing 13 Selection of Materials 15 Selection of Manufacturing Processes 18 Computer-integrated Manufacturing 26 Quality Assurance and Total Quality Management 29 Lean Production and Agile Manufacturing 32 Manufacturing Costs and Global Competition 32 General Trends in Manufacturing 34

Part

l:

1

The Structure of Metals

Fundamentals of Materials: Their Behavior and Manufacturing Properties 37 40

Introduction 40 1.2 Types of Atomic Bonds 41 1.3 The Crystal Structure of Metals 42 1.4 Deformation and Strength of Single Crystals 44 1.5 Grains and Grain Boundaries 47 1.6 Plastic Deformation of Polycrystalline Metals 50 1.7 Recovery, Recrystallization, and Grain Growth 51 1.8 Cold, Warm, and Hot Working 52 Summary 53 Key Terms 53 Bibliography 54 Review Questions 54 Qualitative Problems 54 Quantitative Problems 55 Synthesis, Design, and Projects 1.1

2

Mechanical Behavior, Testing, ancl Manufacturing Properties of Materials 2.1

2.2 2.3

11

Introduction 56 Tension 57 Compression 66 XIX

56

55

Torsion 67 Bending (Flexure) 68 Hardness 68 Fatigue 74 2.8 Creep 75 2.9 Impact 75 2.10 Failure and Fracture of Materials in Manufacturing and in Service 76 Residual Stresses 81 2.11 Work, Heat, and Temperature 82 2.12 Bibliography 84 Summary 83 Key Terms 84 Qualitative Problems 85 Review Questions 84 Quantitative Problems 85 Synthesis, Design, and Projects

2.4 2.5 2.6 2.7

Physical Properties of Materials 3.1 3.2 3.3

Introduction

86

88

88

Density 89 Melting Point 92 3.4 Specific Heat 92 3.5 Thermal Conductivity 93 3.6 Thermal Expansion 93 Electrical, Magnetic, and Optical Properties 94 3.7 3.8 Corrosion Resistance 95 Bibliography 98 Summary 97 Key Terms 97 Qualitative Problems 98 Review Questions 98 Quantitative Problems 98 Synthesis, Design, and Projects

99

Metal Alloys: Their Structure and Strengthening 100 by Heat Treatment 4.1

4.2 4.3

4.4 4.5 4.6 4.7 4.8

4.9 4.10 4.11 4.12 4.13

100 Structure of Alloys 101 Phase Diagrams 103 The Iron-Carbon System 107 The Iron-Iron-carbide Phase Diagram and the Development of Microstructures in Steels 108 Cast Irons 110 Heat Treatment of Ferrous Alloys 111 Hardenability of Ferrous Alloys 1 15 Heat Treatment of Nonferrous Alloys and Stainless Steels 117 Case Hardening 119 Annealing 121 Heat-treating Furnaces and Equipment 123 Design Considerations for Heat Treating 125

Introduction

XX

Key Terms 127 Bibliography 127 Summary 126 Review Questions 127 Qualitative Problems 127 Quantitative Problems 128 Synthesis, Design, and Projects

128

Ferrous Metals and Alloys; Production, General Properties, and Applications 129 5.1 5.2 5.3

5.4 5.5

Introduction 129 Production of Iron and Steel 130 Casting of Ingots 133 Continuous Casting 134 Carbon and Alloy Steels 136

5.6 Stainless Steels 143 5.7 Tool and Die Steels 145 Summary 147 Key Terms 148 Bibliography 148 Review Questions 148 Qualitative Problems 149 Quantitative Problems 149 Synthesis, Design, and Projects

150

Nonferrous Metals and Alloys: Production, General Properties, and Applications 151 6.1 6.2 6.3 6.4 6.5 6.6

6.7 6.8 6.9

Introduction 151 Aluminum and Aluminum Alloys 152 Magnesium and Magnesium Alloys 157 Copper and Copper Alloys 158 Nickel and Nickel Alloys 160 Superalloys 161 Titanium and Titanium Alloys 162 Refractory Metals and Alloys 163 Beryllium

164

Zirconium 164 6.11 Low-melting Alloys 164 Precious Metals 166 6.12 6.13 Shape-memory Alloys (Smart Materials) 166 6.14 Amorphous Alloys (Metallic Glasses) 167 6.15 Metal Foams 167 Summary 168 Key Terms 168 Bibliography 169 Review Questions 169 Qualitative Problems 169 Quantitative Problems 170 Synthesis, Design, and Projects 6.10

Polymers: Structure, General Properties, and Applications 171 7.1 7.2 7.3 7.4

Introduction 171 The Structure of Polymers 173 Thermoplastics 180 Thermosetting Plastics 184

XXI

170

Additives in Plastics 184 General Properties and Applications of Thermoplastics General Properties and Applications of Thermosetting 7.7 Plastics 188 Biodegradable Plastics 190 7.8 Elastomers (Rubbers) 191 7.9 Key Terms 193 Bibliography 193 Summary 192 Qualitative Problems 194 Review Questions 194 Synthesis, Design, and Projects Quantitative Problems 195 7.5 7.6

8

195

Ceramics, Graphite, Diamond, and Nanomaterials: Structure, General Properties, and Applications 196 8.1 8.2 8.3 8.4 8.5 8.6 8.7 8.8

Introduction 196 The Structure of Ceramics 197 General Properties and Applications of Ceramics Glasses 205 Glass Ceramics Graphite 208

201

207

Diamond 210 Nanomaterials 210 Bibliography 213 Summary 212 Key Terms 212 Qualitative Problems 214 Review Questions 213 Quantitative Problems 214 Synthesis, Design, and Projects

9

185

214

Composite Materials: Structure, General Properties, and Applications 216 Introduction 216 The Structure of Reinforced Plastics 217 Properties of Reinforced Plastics 222 Applications of Reinforced Plastics 225 Metal-matrix Composites 227 Ceramic-matrix Composites 229 9.7 Other Composites 230 Key Terms 231 Bibliography 231 Summary 231 Qualitative Problems 232 Review Questions 232 Synthesis, Design, and Projects Quantitative Problems 233 9.1 9.2 9.3 9.4 9.5 9.6

Part II: Metal-Casting Processes ancl Equipment 235

l0

Fundamentals of Metal Casting 10.1 10.2

Introduction

237 Solidification of Metals xxii

238

237

233

Fluid Flow 243 Fluidity of Molten Metal 245 Heat Transfer 247 10.6 Defects 249 Summary 253 Key Terms 254 Bibliography 254 Review Questions 254 Qualitative Problems 255 Quantitative Problems 25 5 Synthesis, Design, and Projects 10.3 10.4 10.5

ll

Metal-Casting Processes and Equipment

256

258

Introduction 258 Expendable-mold, Permanent-pattern Casting Processes 262 Expendable-mold, Expendable-pattern Casting Processes 270 Permanent-mold Casting Processes 277 Casting Techniques for Single-crystal Components 285 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 291 Qualitative Problems 291 Quantitative Problems 292 Synthesis, Design, and Projects 292 11.1 11.2 11.3 11.4 11.5

I2

Metal Casting: Design, Materials, and Economics 294 Introduction 294 Design Considerations in Casting 294 Casting Alloys 302 Economics of Casting 307 Summary 308 Key Terms 309 Bibliography 309 Review Questions 309 Qualitative Problems 309 Quantitative Problems 310 Synthesis, Design, and Projects 12.1 12.2 12.3 12.4

310

Part Ill: Forming and Shaping Processes and Equipment 313 1

3

Metal-Rolling Processes and Equipment 13.1 13.2 13.3

Introduction

316

316

The Flat-rolling Process 318 Flat-rolling Practice 322 13.4 Rolling Mills 325 13.5 Various Rolling Processes and Mills 327 Summary 332 Key Terms 333 Bibliography 333 Review Questions 333 Qualitative Problems 333 Quantitative Problems 334 Synthesis, Design, and Projects xxiii

334

Metal-Forging Processes and Equipment Introduction 335 Open-die Forging 337 14.3 Impression-die and Closed-die Forging 339 14.4 Various Forging Operations 343 14.5 Forgeability of Metals; Forging Defects 348 14.6 Die Design, Die Materials, and Lubrication 349 14.7 Die-manufacturing Methods and Die Failures 351 14.8 Forging Machines 353 14.9 Economics of Forging 355 358 Bibliography 358 Summary 357 Key Terms Qualitative Problems 358 Review Questions 358 Quantitative Problems 359 Syntbesis, Design, and Projects

335

14.1 14.2

359

Metal Extrusion and Drawing Processes and Equipment 360 Introduction 360 The Extrusion Process 362 15.3 Hot Extrusion 364 15.4 Cold Extrusion 368 15.5 Extrusion Defects 371 15.6 Extrusion Equipment 373 15.7 The Drawing Process 373 15.8 Drawing Practice 375 15.9 Drawing Defects and Residual Stresses 377 15.10 Drawing Equipment 377 Bibliography 379 Summary 378 Key Terms 378 Review Questions 379 Qualitative Problems 379 Quantitative Problems 380 Syntbesis, Design, and Projects 15.1

15.2

Sheet-Metal Forming Processes and Equipment 381 16.1 16.2 16.3 16.4 16.5 16.6

16.7 16.8 16.9 16.10 16.11

Introduction

381 Shearing 382 Sheet-metal Characteristics and Formability 392 Forrnability Tests for Sheet Metals 394 Bending Sheets, Plates, and Tubes 397 Miscellaneous Bending and Related Operations 401 Deep Drawing 407 Rubber Forming and Hydroforming 413 Spinning 417 Superplastic Forming 420 Specialized Forming Processes 421 XXIV

380

16.12 Manufacturing of Metal Honeycomb Structures 426 16.13 Design Considerations in Sheet-metal Forming 428 16.14 Equipment for Sheet-metal Forming 430 16.15 Economics of Sheet-forming Operations 431 Summary 432 Key Terms 433 Bibliography 433 Review Questions 434 Qualitative Problems 434 Quantitative Problems 435 Synthesis, Design, and Projects 435

Powder-Metal Processing and Equipment

437

Introduction 437 Production of Metal Powders 438 Compaction of Metal Powders 444 Sintering 452 Secondary and Finishing Operations 456 Design Considerations 457 17.7 Process Capabilities 459 17.8 Economics of Powder Metallurgy 460 Summary 462 Key Terms 462 Bibliography 463 Review Questions 463 Qualitative Problems 463 Quantitative Problems 464 Synthesis, Design, ana' Projects

464

17.1 17.2 17.3 17.4 17.5 17.6

Ceramics, Glasses, and Superconductors: Processing and Equipment 465 Introduction

465 Shaping Ceramics 466 Forming and Shaping of Glass 472 Techniques for Strengthening and Annealing Glass 476 Design Considerations for Ceramics and Glasses 478 Processing of Superconductors 479 Summary 480 Key Terms 481 Bibliography 481 Revieu/ Questions 482 Qualitative Problems 482 Quantitative Problems 482 Synthesis, Design, and Projects 483 18.1 18.2 18.3 18.4 18.5 18.6

Plastics and Composite Materials: Forming

and Shaping 19.1 19.2 19.3 19.4 19.5 19.6

19.7 19.8 19.9

484

Introduction 484 Extrusion 486 Injection Molding 493 Blow Molding 499 Rotational Molding 501 Thermoforming ...