General Introduction

I.1 What is Manufacturing?

I.2 Product Design and Concurrent Engineering

I.3 Design for Manufacture, Assembly, Disassembly, and Service

I.4 Environmentally Conscious Design, Sustainable Manufacturing,and Product Life Cycle

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

PART 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

2. Mechanical Behavior, Testing, and Manufacturing Properties ofMaterials

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

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

4. Metal Alloys: Their Structure and Strengthening by HeatTreatment

4.1 Introduction

4.2 Structure of Alloys

4.3 Phase Diagrams

4.4 The Iron-Carbon System

4.5 The IronIron-carbide Phase Diagram and the Development ofMicrostructures 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

5. Ferrous Metals and Alloys: Production, General Properties, andApplications

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

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 Lithium

6.12 Low-melting Alloys

6.13 Precious Metals

6.14 Shape-memory Alloys (Smart Materials)

6.15 Amorphous Alloys (Metallic Glasses)

6.16 Metal Foams and Metamaterials

6.17 Rare Earth Metals

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)

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

9. Composite Materials: Structure, General Properties, andApplications

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

PART II: METAL-CASTING PROCESSESAND 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

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

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

PART III: FORMING AND SHAPINGPROCESSES 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

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

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

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

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

18. Ceramics, Glasses, and Superconductors: Processing andEquipment

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

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

19.15 Design Considerations

19.16 Economics of Processing Plastics and Composite Materials

20. Additive Manufacturing

20.1 Introduction

20.2 Additive Manufacturing Methodology

20.3 Extrusion-based Processes

20.4 Photopolymerization

20.5 Material Jetting

20.6 Powder Bed Processes

20.7 Laminated-object Manufacturing

20.8 Miscellaneous Processes

20.9 Emerging AM Applications

20.10 Direct Manufacturing and Rapid Tooling

20.11 Design for Additive Manufacturing

20.12 Additive Manufacturing Economics

PART IV: MACHINING PROCESSES ANDMACHINE 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

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

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

24. Machining Processes: Milling, Broaching, Sawing, Filing, andGear Manufacturing

24.1 Introduction

24.2 Milling and Milling Machines

24.3 Planing and Shaping

24.4 Broaching and Broaching Machines

24.5...