DeGarmo's MATERIALS AND PROCESSES IN MANUFACTURING TENTH EDITIONPDF电子书下载

Chapter 1 Introduction to DeGarmo’s Materials and Processes in Manufacturing 1

1.1 Materials，Manufacturing，and the Standard of Living 1

1.2 Manufacturing and Production Systems 3

Case Study Famous Manufacturing Engineers 27

Chapter 2 Properties of Materials 28

2.1 Introduction 28

2.2 Static Properties 30

2.3 Dynamic Properties 42

2.4 Temperature Effects（Both High and Low） 47

2.5 Machinability Formability，and Weldability 50

2.6 Fracture Toughness and the Fracture Mechanics Approach 50

2.7 Physical Properties 52

2.8 Testing Standards and Concerns 53

Case Study Separation of Mixed Materials 55

Chapter 3 Nature of Metals and Alloys 56

3.1 Structure-Property-Processing-Performance Relationships 56

3.2 The Structure of Atoms 57

3.3 Atomic Bonding 57

3.4 Secondary Bonds 59

3.5 Atom Arrangements in Materials 59

3.6 Crystal Structures of Metals 59

3.7 Development of a Grain Structure 61

3.8 Elastic Deformation 62

3.9 Plastic Deformation 63

3.10 Dislocation Theory of Slippage 64

3.11 Strain Hardening or Work Hardening 64

3.12 Plastic Deformation in Polycrystalline Metals 65

3.13 Grain Shape and Anisotropic Properties 66

3.14 Fracture of Metals 66

3.15 Cold Working，Recrystallization，and Hot Working 66

3.16 Grain Growth 68

3.17 Alloys and Alloy Types 68

3.18 Atomic Structure and Electrical Properties 68

Chapter 4 Equilibrium Phase Diagrams and the Iron-Carbon System 71

4.1 Introduction 71

4.2 Phases 71

4.3 Equilibrium Phase Diagrams 71

4.4 Iron-Carbon Equilibrium Diagram 79

4.5 Steels and the Simplified Iron-Carbon Diagram 80

4.6 Cast Irons 82

Case Study The Blacksmith Anvils 88

Chapter 5 Heat Treatment 89

5.1 Introduction 89

5.2 Processing Heat Treatments 89

5.3 Heat Treatments Used to Increase Strength 92

5.4 Strengthening Heat Treatments for Nonferrous Metals 93

5.5 Strengthening Heat Treatments for Steel 96

5.6 Surface Hardening of Steel 109

5.7 Furnaces 112

5.8 Heat Treatment and Energy 114

Case Study A Carpenter’s Claw Hammer 116

Chapter 6 Ferrous Metals and Alloys 118

6.1 Introduction to History-Dependent Materials 118

6.2 Ferrous Metals 118

6.3 Iron 119

6.4 Steel 120

6.5 Stainless Steels 132

6.6 Tool Steels 134

6.7 Alloy Cast Steels and Irons 136

Case Study Interior Tub of a Top-Loading Washing Machine 138

Chapter 7 Nonferrous Metals and Alloys 139

7.1 Introduction 139

7.2 Copper and Copper Alloys 140

7.3 Aluminum and Aluminum Alloys 144

7.4 Magnesium and Magnesium Alloys 152

7.5 Zinc-Based Alloys 154

7.6 Titanium and Titanium Alloys 155

7.7 Nickel-Based Alloys 157

7.8 Superalloys and Other Metals Designed for High-Temperature Service 157

7.9 Lead and Tin，and Their Alloys 158

7.10 Some Lesser Known Metals and Alloys 159

7.11 Metallic Glasses 159

7.12 Graphite 160

Case Study Nonsparking Wrench 161

Chapter 8 Nonmetallic Materials：Plastics，Elastomers，Ceramics，and Composites 162

8.1 Introduction 162

8.2 Plastics 163

8.3 Elastomers 173

8.4 Ceramics 175

8.5 Composite Materials 182

Case Study Two-Wheel Dolly Handles 194

Chapter 9 Material Selection 195

9.1 Introduction 195

9.2 Material Selection and Manufacturing Processes 197

9.3 The Design Process 199

9.4 Procedures for Material Selection 200

9.5 Additional Factors to Consider 203

9.6 Consideration of the Manufacturing Process 204

9.7 Ultimate Objective 205

9.8 Materials Substitution 207

9.9 Effect of Product Liability on Materials Selection 207

9.10 Aids to Material Selection 208

Case Study Material Selection 212

Chapter 10 Measurement and Inspection and Testing 213

10.1 Introduction 213

10.2 Standards of Measurement 214

10.3 Allowance and Tolerance 220

10.4 Inspection Methods for Measurement 227

10.5 Measuring Instruments 229

10.6 Vision Systems for Measurement 238

10.7 Coordinate Measuring Machines 240

10.8 Angle-Measuring Instruments 240

10.9 Gages for Attributes Measuring 242

10.10 Testing 245

10.11 Visual Inspection 247

10.12 Liquid Penetrant Inspection 247

10.13 Magnetic Particle Inspection 248

10.14 Ultrasonic Inspection 250

10.15 Radiography 252

10.16 Eddy-Current Testing 253

10.17 Acoustic Emission Monitoring 255

10.18 Other Methods of Nondestructive Testing and Inspection 256

10.19 Dormant versus Critical Flaws 257

Case Study Measuring An Angle 261

Chapter 11 Fundamentals of Casting 262

11.1 Introduction to Materials Processing 262

11.2 Introduction to Casting 263

11.3 Casting Terminology 265

11.4 The Solidification Process 266

11.5 Patterns 276

11.6 Design Considerations in Castings 278

11.7 The Casting Industry 280

Case Study The Cast Oil-Field Fitting 282

Chapter 12 Expendable-Mold Casting Processes 283

12.1 Introduction 283

12.2 Sand Casting 283

12.3 Cores and Core Making 298

12.4 Other Expendable-Mold Processes with Multiple-Use Patterns 302

12.5 Expendable-Mold Processes Using Single-Use Patterns 304

12.6 Shakeout，Cleaning，and Finishing 310

12.7 Summary 310

Case Study Movable and Fixed Jaw Pieces for a Heavy-Duty Bench Vise 312

Chapter 13 Multiple-Use-Mold Casting Processes 313

13.1 Introduction 313

13.2 Permanent-Mold Casting 313

13.3 Die Casting 316

13.4 Squeeze Casting and Semisolid Casting 320

13.5 Centrifugal Casting 322

13.6 Continuous Casting 324

13.7 Melting 325

13.8 Pouring Practice 328

13.9 Cleaning，Finishing，and Heat Treating of Castings 329

13.10 Automation in Foundry Operations 330

13.11 Process Selection 330

Case Study Baseplate for a Household Steam Iron 333

Chapter 14 Fabrication of Plastics，Ceramics，and Composites 334

14.1 Introduction 334

14.2 Fabrication of Plastics 334

14.3 Processing of Rubber and Elastomers 346

14.4 Processing of Ceramics 347

14.5 Fabrication of Composite Materials 351

Case Study Fabrication of Lavatory Wash Basins 362

Chapter 15 Fundamentals of Metal Forming 363

15.1 Introduction 363

15.2 Forming Processes：Independent Variables 364

15.3 Dependent Variables 366

15.4 Independent-Dependent Relationships 366

15.5 Process Modeling 367

15.6 General Parameters 368

15.7 Friction and Lubrication under Metalworking Conditions 369

15.8 Temperature Concerns 371

Case Study Repairs to a Damaged Propeller 380

Chapter 16 Bulk Forming Processes 381

16.1 Introduction 381

16.2 Classification of Deformation Processes 381

16.3 Bulk Deformation Processes 382

16.4 Rolling 382

16.5 Forging 389

16.6 Extrusion 401

16.7 Wire，Rod，and Tube Drawing 406

16.8 Cold Forming，Cold Forging，and Impact Extrusion 409

16.9 Piercing 413

16.10 Other Squeezing Processes 414

16.11 Surface Improvement by Deformation Processing 416

Case Study Handle and Body of a Large Ratchet Wrench 420

Chapter 17 Sheet-Forming Processes 421

17.1 Introduction 421

17.2 Shearing Operations 421

17.3 Bending 430

17.4 Drawing and Stretching Processes 437

17.5 Alternative Methods of Producing Sheet-Type Products 451

17.6 Pipe Welding 451

17.7 Presses 452

Case Study Fabrication of a One-Piece Brass Flashlight Case 459

Chapter 18 Powder Metallurgy 460

18.1 Introduction 460

18.2 The Basic Process 461

18.3 Powder Manufacture 461

18.4 Rapidly Solidified Powder（Microcrystalline and Amorphous） 463

18.5 Powder Testing and Evaluation 463

18.6 Powder Mixing and Blending 463

18.7 Compacting 464

18.8 Sintering 468

18.9 Hot-Isostatic Pressing 469

18.10 Other Techniques to Produce High-Density P/M Products 470

18.11 Metal Injection Molding（MIM）or Powder Injection Molding（PIM） 471

18.12 Secondary Operations 473

18.13 Properties of P/M Products 475

18.14 Design of Powder Metallurgy Parts 476

18.15 Powder Metallurgy Products 478

18.16 Advantages and Disadvantages of Powder Metallurgy 478

18.17 Process Summary 480

Case Study Impeller for an Automobile Water Pump 483

Chapter 19 Electronic Electrochemical Chemical and Thermal Machining Processes 484

19.1 Introduction 484

19.2 Chemical Machining Processes 485

19.3 Electrochemical Machining Processes 504

19.4 Electrical Discharge Machining 510

Case Study Fire Extinguisher Pressure Gage 522

Chapter 20 Fundamentals of Machining/Orthogonal Machining 523

20.1 Introduction 523

20.2 Fundamentals 524

20.3 Energy and Power in Machining 533

20.4 Orthogonal Machining（Two Forces） 538

20.5 Merchant’s Model 542

20.6 Mechanics of Machining（Statics） 543

20.7 Shear Strain γ and Shear Front Angle？ 545

20.8 Mechanics of Machining（Dynamics） 547

20.9 Summary 556

Case Study Orthogonal Plate Machining Experiment at Auburn University 559

Chapter 21 Cutting Tools for Machining 560

21.1 Introduction 560

21.2 Cutting-Tool Materials 565

21.3 Tool Geometry 577

21.4 Tool Coating Processes 578

21.5 Tool Failure and Tool Life 582

21.6 Flank Wear 583

21.7 Economics of Machining 588

21.8 Cutting Fluids 591

Case Study Comparing Tool Materials Based on Tool Life 597

Chapter 22 Turning and Boring Processes 598

22.1 Introduction 598

22.2 Fundamentals of Turning，Boring，and Facing Turning 600

22.3 Lathe Design and Terminology 607

22.4 Cutting Tools for Lathes 614

22.5 Workholding in Lathes 619

Case Study Estimating the Machining Time for Turning 627

Chapter 23 Drilling and Related Hole-Making Processes 628

23.1 Introduction 628

23.2 Fundamentals of the Drilling Process 629

23.3 Types of Drills 631

23.4 Tool Holders for Drills 643

23.5 Workholding for Drilling 645

23.6 Machine Tools for Drilling 645

23.7 Cutting Fluids for Drilling 649

23.8 Counterboring，Countersinking，and Spot Facing 650

23.9 Reaming 651

Case Study Bolt-down Leg on a Casting 655

Chapter 24 Milling 656

24.1 Introduction 656

24.2 Fundamentals of Milling Processes 656

24.3 Milling Tools and Cutters 663

24.4 Machines for Milling 669

Case Study HSS versus Tungsten Carbide Milling 676

Chapter 25 Workholding Devices for Machine Tools 677

25.1 Introduction 677

25.2 Conventional Fixture Design 677

25.3 Design Steps 680

25.4 Clamping Considerations 682

25.5 Chip Disposal 683

25.6 Unloading and Loading Time 684

25.7 Example of Jig Design 684

25.8 Types of Jigs 686

25.9 Conventional Fixtures 688

25.10 Modular Fixturing 690

25.11 Setup and Changeover 691

25.12 Clamps 694

25.13 Other Workholding Devices 694

25.14 Economic Justification of Jigs and Fixtures 698

Case Study Fixture versus No Fixture in Milling 701

Chapter 26 Numerical Control（NC）and the A（4）Level of Automation 702

26.1 Introduction 702

26.2 Basic Principles of Numerical Control 710

26.3 Machining Center Features and Trends 721

26.4 Ultra-High-Speed Machining Centers（UHSMCs） 725

26.5 Summary 726

Case Study Process Planning for the MfE 730

Chapter 27 Other Machining Processes 731

27.1 Introduction 731

27.2 Introduction to Shaping and Planing 731

27.3 Introduction to Broaching 736

27.4 Fundamentals of Broaching 737

27.5 Broaching Machines 742

27.6 Introduction to Sawing 743

27.7 Introduction to Filing 751

Case Study Cost Estimating—Planing vs.Milling 755

Chapter 28 Abrasive Machining Processes 756

28.1 Introduction 756

28.2 Abrasives 757

28.3 Grinding Wheel Structure and Grade 763

28.4 Grinding Wheel Identification 767

28.5 Grinding Machines 771

28.6 Honing 780

28.7 Superfinishing 781

28.8 Free Abrasives 783

Case Study Overhead Crane Installation 789

Chapter 29 Thread and Gear Manufacturing 790

29.1 Introduction 790

29.2 Thread Making 795

29.3 Internal Thread Cutting-Tapping 798

29.4 Thread Milling 803

29.5 Thread Grinding 805

29.6 Thread Rolling 805

29.7 Gear Making 808

29.8 Gear Types 811

29.9 Gear Manufacturing 812

29.10 Machining of Gears 813

29.11 Gear Finishing 821

29.12 Gear Inspection 823

Case Study Bevel Gear for a Riding Lawn Mower 826

Chapter 30 Fundamentals of Joining 827

30.1 Introduction to Consolidation Processes 827

30.2 Classification of Welding and Thermal Cutting Processes 828

30.3 Some Common Concerns 828

30.4 Types of Fusion Welds and Types of Joints 829

30.5 Design Considerations 832

30.6 Heat Effects 832

30.7 Weldability or Joinability 839

30.8 Summary 840

Chapter 31 Gas Flame and Arc Processes 842

31.1 Oxyfuel-Gas Welding 842

31.2 Oxygen Torch Cutting 846

31.3 Flame Straightening 848

31.4 Arc Welding 849

31.5 Consumable-Electrode Arc Welding 851

31.6 Nonconsumable-Electrode Arc Welding 859

31.7 Welding Equipment 864

31.8 Arc Cutting 865

31.9 Metallurgical and Heat Effects in Thermal Cutting 867

Case Study Bicycle Frame Construction and Repair 870

Chapter 32 Resistance and Solid-State Welding Processes 871

32.1 Introduction 871

32.2 Theory of Resistance Welding 871

32.3 Resistance Welding Processes 874

32.4 Advantages and Limitations of Resistance Welding 879

32.5 Solid-State Welding Processes 879

Case Study Field Repair to a Power Transformer 888

Chapter 33 Other Welding Processes，Brazing and Soldering 889

33.1 Introduction 889

33.2 Other Welding and Cutting Processes 889

33.3 Surface Modification by Welding-Related Processes 898

33.4 Brazing 901

33.5 Soldering 909

Chapter 34 Adhesive Bonding，Mechanical Fastening，and Joining of Nonmetals 915

34.1 Adhesive Bonding 915

34.2 Mechanical Fastening 924

34.3 Joining of Plastics 927

34.4 Joining of Ceramics and Glass 929

34.5 Joining of Composites 929

Case Study Golf Club Heads with Insert 932

Chapter 35 Surface Engineering 933

35.1 Introduction 933

35.2 Mechanical Cleaning and Finishing Blast Cleaning 940

35.3 Chemical Cleaning 946

35.4 Coatings 948

35.5 Vaporized Metal Coatings 958

35.6 Clad Materials 958

35.7 Textured Surfaces 959

35.8 Coil-Coated Sheets 959

35.9 Edge Finishing and Burrs 959

35.10 Surface Integrity 961

Case Study Dana Lynn’s Fatigue Lesson 967

Chapter 36 Quality Engineering 969

36.1 Introduction 969

36.2 Determining Process Capability 970

36.3 Inspection to Control Quality 981

36.4 Process Capability Determination from Control Chart Data 985

36.5 Determining Causes for Problems in Quality 986

36.6 Summary 996

Case Study Boring QC Chart Blunders 1000

Index 1001