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