1 INTRODUCTION AND OVERVIEW OF MANUFACTURING

1.1 What Is Manufacturing?

1.2 Materials in Manufacturing

1.3 Manufacturing Processes

1.4 Production Systems

1.5 Manufacturing Economics

Part I Engineering Materials and Product Attributes

2 THE NATURE OF MATERIALS

2.1 Atomic Structure and the Elements

2.2 Bonding between Atoms and Molecules

2.3 Crystalline Structures

2.4 Noncrystalline (Amorphous) Structures

2.5 Engineering Materials

3 MECHANICAL PROPERTIES OF MATERIALS

3.1 Stress-Strain Relationships

3.2 Hardness

3.3 Effect of Temperature on Properties

3.4 Fluid Properties

3.5 Viscoelastic Behavior of Polymers

4 PHYSICAL PROPERTIES OF MATERIALS

4.1 Volumetric and Melting Properties

4.2 Thermal Properties

4.3 Mass Diffusion

4.4 Electrical Properties

4.5 Electrochemical Processes

5 ENGINEERING MATERIALS

5. 1 Metals and Their Alloys

5.2 Ceramics

5.3 Polymers

5.4 Composite Materials

6 DIMENSIONS, SURFACES, AND THEIR MEASUREMENT

6.1 Dimensions, Tolerances, and Related Attributes

6.2 Conventional Measuring Instruments and Gages

6.3 Surfaces

6.4 Measurement of Surfaces

6.5 Effect of Manufacturing Processes

Part II Solidification Processes

7 FUNDAMENTALS OF METAL CASTING

7.1 Overview of Casting Technology

7.2 Heating and Pouring

7.3 Solidification and Cooling

8 METAL CASTING PROCESSES

8.1 Sand Casting

8.2 Other Expendable-Mold Casting Processes

8.3 Permanent-Mold Casting Processes

8.4 Foundry Practice

8.5 Casting Quality

8.6 Castability and Casting Economics

8.7 Product Design Considerations

9 GLASSWORKING

9.1 Raw Materials Preparation and Melting

9.2 Shaping Processes in Glassworking

9.3 Heat Treatment and Finishing

9.4 Product Design Considerations

10 SHAPING PROCESSES FOR PLASTICS

10.1 Properties of Polymer Melts

10.2 Extrusion

10.3 Production of Sheet and Film

10.4 Fiber and Filament Production (Spinning)

10.5 Coating Processes

10.6 Injection Molding

10.7 Compression and Transfer Molding

10.8 Blow Molding and Rotational Molding

10.9 Thermoforming

10.10 Casting

10.11 Polymer Foam Processing and Forming

10.12 Product Design Considerations

11 PROCESSING OF POLYMER MATRIX COMPOSITES AND RUBBER

11.1 Overview of PMC Processing

11.2 Open-Mold Processes

11.3 Closed-Mold Processes

11.4 Other PMC Shaping Processes

11.5 Rubber Processing and Shaping

11.6 Manufacture of Tires and Other Rubber Products

Part III Particulate Processing of Metals and Ceramics

12 POWDER METALLURGY

12.1 Characterization of Engineering Powders

12.2 Production of Metallic Powders

12.3 Conventional Pressing and Sintering

12.4 Alternative Pressing and Sintering Techniques

12.5 Powder Metallurgy Materials and Economics

12.6 Product Design Considerations in Powder Metallurgy

13 PROCESSING OF CERAMICS AND CERMETS

13.1 Processing of Traditional Ceramics

13.2 Processing of New Ceramics

13.3 Processing of Cermets

13.4 Product Design Considerations

Part IV Metal Forming and Sheet Metalworking

14 FUNDAMENTALS OF METAL FORMING

14.1 Overview of Metal Forming

14.2 Material Behavior in Metal Forming

14.3 Temperature in Metal Forming

14.4 Strain Rate Sensitivity

14.5 Friction and Lubrication in Metal Forming

14.6 Forming Limit Diagram

15 BULK DEFORMATION PROCESSES IN METAL WORKING

15.1 Rolling

15.2 Forging

15.3 Extrusion

15.4 Wire and Bar Drawing

16 SHEET METALWORKING

16.1 Cutting Operations

16.2 Bending Operations

16.3 Drawing

16.4 Equipment and Economics for Sheet-Metal Pressworking

16.5 Other Sheet-Metal-Forming Operations

16.6 Sheet-Metal Operations Not Performed on Presses

16.7 Bending of Tube Stock

Part V Material Removal Processes

17 THEORY OF METAL MACHINING

17.1 Overview of Machining Technology

17.2 Theory of Chip Formation in Metal Machining

17.3 Force Relationships and the Merchant Equation

17.4 Power and Energy Relationships in Machining

17.5 Cutting Temperature

18 MACHINING OPERATIONS AND MACHINE TOOLS

18.1 Machining and Part Geometry

18.2 Turning and Related Operations

18.3 Drilling and Related Operations

18.4 Milling

18.5 Machining Centers and Turning Centers

18.6 Other Machining Operations

18.7 Machining Operations for Special Geometries

18.8 High-Speed Machining

19 CUTTING-TOOL TECHNOLOGY

19.1 Tool Life

19.2 Tool Materials

19.3 Tool Geometry

19.4 Cutting Fluids

20 ECONOMIC AND PRODUCT DESIGN CONSIDERATIONS IN MACHINING

20.1 Machinability

20.2 Tolerances and Surface Finish

20.3 Machining Economics

20.4 Product Design Considerations in Machining

21 GRINDING AND OTHER ABRASIVE PROCESSES

21.1 Grinding

21.2 Related Abrasive Processes

22 NONTRADITIONAL MACHINING AND THERMAL CUTTING PROCESSES

22.1 Mechanical Energy Processes

22.2 Electrochemical Machining Processes

22.3 Thermal Energy Processes

22.4 Chemical Machining

22. 5 Hybrid Machining Systems

22.6 Application Considerations

Part VI Property Enhancing and Surface Processing Operations

23 HEAT TREATMENT OF METALS

23.1 Annealing

23.2 Martensite Formation in Steel

23.3 Precipitation Hardening

23.4 Surface Hardening

23.5 Heat Treatment Methods and Facilities

24 SURFACE PROCESSING OPERATIONS

24.1 Industrial Cleaning Processes

24.2 Diffusion and Ion Implantation

24.3 Plating and Related Processes

24.4 Conversion Coating

24.5 Vapor Deposition Processes

24.6 Organic Coatings

24.7 Porcelain Enameling and Other Ceramic Coatings

24.8 Thermal and Mechanical Coating Processes

Part VII Joining and Assembly Processes

25 FUNDAMENTALS OF WELDING AND WELDING PROCESSES

25.1 Overview of Welding Technology

25.2 The Weld Joint

25.3 Physics of Welding

25.4 Features of a Fusion-Welded Joint

25.5 Arc Welding

25.6 Resistance Welding

25.7 Oxyfuel Gas Welding

25.8 Other Fusion-Welding Processes

25.9 Solid-State Welding

25.10 Weld Quality

25.11 Weldability and Welding Economics

25.12 Design Considerations in Welding

26 BRAZING, SOLDERING, AND ADHESIVE BONDING

26.1 Brazing

26.2 Soldering

26.3 Adhesive Bonding

27 MECHANICAL ASSEMBLY

27.1 Threaded Fasteners

27.2 Rivets and Eyelets

27.3 Assembly Methods Based on Interference Fits

27.4 Other Mechanical Fastening Methods

27.5 Molding Inserts and Integral Fasteners

27.6 Design for Assembly

27.7 DFMA Guidelines

Part VIII Special Processing and Assembly Technologies (Available in e-text for students)

28 ADDITIVE MANUFACTURING

28.1 Fundamentals of Additive Manufacturing

28.2 Additive Manufacturing Technologies

28.3 Cycle Time and Cost Analysis

28.4 Additive Manufacturing Applications

28.5 File formats of Additive Manufacturing

29 PROCESSING OF INTEGRATED CIRCUITS

29.1 Overview of IC Processing

29.2 Silicon Processing

29.3 Lithography

29.4 Layer Processes Used in IC Fabrication

29.5 Integrating the Fabrication Steps

29.6 IC Packaging

29.7 Yields in IC Processing

30 ELECTRONICS ASSEMBLY AND PACKAGING

30.1 Electronics Packaging

30.2 Printed Circuit Boards

30.3 Printed Circuit Board Assembly

30.4 Electrical Connector Technology

31 MICROFABRICATION TECHNOLOGIES

31.1 Microsystem Products

31.2 Microfabrication Processes

REFERENCES

REVIEW QUESTIONS

32 NANOFABRICATION TECHNOLOGIES

32.1 Nanotechnology Products and Applications

32.2 Introduction to Nanoscience

32.3 Nanofabrication Processes

Part IX Manufacturing Systems

33 AUTOMATION TECHNOLOGIES FOR MANUFACTURING SYSTEMS

33.1 Automation Fundamentals

33.2 Hardware for Automation

33.3 Computer Numerical Control

33.4 Industrial Robotics

34 INTEGRATED MANUFACTURING SYSTEMS

34.1 Material Handling

34.2 Fundamentals of Production Lines

34.3 Manual Assembly Lines

34.4 Automated Production Lines

34.5 Cellular Manufacturing

34.6 Flexible Manufacturing Systems

34.7 Computer-Integrated Manufacturing

34.7.1 Protocols used in Integrated Manufacturing

Part X Manufacturing Support Systems

35 PROCESS PLANNING AND PRODUCTION CONTROL

35.1 Process Planning

35.2 Other Manufacturing Engineering Functions

35.3 Production Planning and Control

35.4 Just-in-Time Delivery Systems

35.5 Lean Production

35.6 Agile Production

REFERENCES

REVIEW QUESTIONS

PROBLEMS

36 QUALITY CONTROL AND INSPECTION

36.1 Product Quality

36.2 Process Capability and Tolerances

36.3 Statistical Process Control