制造工程与技术——热加工 1
影印改编版序 1
General Introduction 1
I.1 What Is Manufacturing? 1
I.2 Product Design and Concurrent Engineering 8
I.3 Design for Manufacture, Assembly, Disassembly, and Service 11
I.4 Green Design and Manufacturing 13
I.5 Selection of Materials 15
I.6 Selection of Manufacturing Processes 18
I.7 Computer-integrated Manufacturing 26
I.8 Quality Assurance and Total QualiManagement 29
I.9 Lean Production and Agile Manufacturing 32
I.10 Manufacturing Costs and Global Competition 32
I.11 General Trends in Manufacturing 34
Metal-Casting Processesand Equipment 37
1Fundamentals of Metal Casting 39
1.1 Introduction 39
1.2 Solidification of Metals 40
1.3 Fluid Flow 45
1.4 Fluidity of Molten Metal 47
1.5 Heat Transfer 49
1.6 Defects 51
Summary 55
Key Terms 56
Bibliography 56
Review Questions 56
Qualitative Problems 57
Quantitative Problems 57
Synthesis, Design, and Projects 58
2Metal-Casting Processes and Equipment 60
2.1 Introduction 60
2.2 Expendable-mold, Permanent-pattern Casting Processes 64
2.3 Expendable-mold, Expendable-pattern Casting Processes 72
2.4 Permanent-mold Casting Processes 79
2.5 Casting Techniques for Single-crystal Components 87
2.6 Rapid Solidification 88
2.7 Inspection of Castings 89
2.8 Melting Practice and Furnaces 89
2.9 Foundries and Foundry Automation 91
Summary 91
Key Terms 92
Bibliography 92
Review Questions 93
Qualitative Problems 93
Quantitative Problems 94
Synthesis, Design, and Projects 94
3Metal Casting: Design, Materials,and Economics 96
3.1 Introduction 96
3.2 Design Considerations in Casting 96
3.3 Casting Alloys 104
3.4 Economics of Casting 109
Summary 110 Key Terms 111 Bibliography 111
Review Questions 111 Qualitative Problems 111
Quantitative Problems 112 Synthesis, Design, and Projects 112
Forming and Shaping Processes and Equipment 115
4Metal-Rolling Processes and Equipment 118
4.1 Introduction 118
4.2 The Flat-rolling Process 120
4.3 Flat-rolling Practice 124
4.4 Rolling Mills 127
4.5 Various Rolling Processes and Mills 129
Summary 134
Key Terms 135
Bibliography 135
Review Questions 135
Qualitative Problems 135
Quantitative Problems 136
Synthesis, Design, and Projects 136
5Metal-Forging Processes and Equipment 137
5.1 Introduction 137
5.2 Open-die Forging 139
5.3 Impression-die and Closed-die Forging 141
5.4 Various Forging Operations 145
5.5 Forgeability of Metals; Forging Defects 150
5.6 Die Design, Die Materials, and Lubrication 151
5.7 Die-manufacturing Methods and Die Failures 153
5.8 Forging Machines 155
5.9 Economics of Forging 157
Summary 159
Key Terms 160
Bibliography 160
Review Questions 160
Qualitative Problems 160
Quantitative Problems 161
Synthesis, Design, and Projects 161
6Metal Extrusion and Drawing Processes and Equipment 162
6.1 Introduction 162
6.2 The Extrusion Process 164
6.3 Hot Extrusion 166
6.4 Cold Extrusion 170
6.5 Extrusion Defects 173
6.6 Extrusion Equipment 175
6.7 The Drawing Process 175
6.8 Drawing Practice 177
6.9 Drawing Defects and Residual Stresses 179
6.10 Drawing Equipment 179
Summary 180
Key Terms 180
Bibliography 181
Review Questions 181
Qualitative Problems 181
Quantitative Problems 182
Synthesis, Design, and Projects 182
7Sheet-Metal Forming Processes and Equipment 183
7.1 Introduction 183
7.2 Shearing 184
7.3 Sheet-metal Characteristics and Formability 194
7.4 Formability Tests for Sheet Metals 196
7.5 Bending Sheets, Plates, and Tubes 199
7.6 Miscellaneous Bending and Related Operations 203
7.7 Deep Drawing 209
7.8 Rubber Forming and Hydroforming 215
7.9 Spinning 219
7.10 Superplastic Forming 222
7.11 Specialized Forming Processes 223
7.12 Manufacturing of Metal Honeycomb Structures 228
7.13 Design Considerations in Sheet-metal Forming 230
7.14 Equipment for Sheet-metal Forming 232
7.15 Economics of Sheet-forming Operations 233
Summary 234
Key Terms 235
Bibliography 235
Review Questions 236
Qualitative Problems 236
Quantitative Problems 237
Synthesis, Design, and Projects 237
8Powder-Metal Processing and Equipment 239
8.1 Introduction 239
8.2 Production of Metal Powders 240
8.3 Compaction of Metal Powders 246
8.4 Sintering 254
8.5 Secondary and Finishing Operations 258
8.6 Design Considerations 259
8.7 Process Capabilities 261
8.8 Economics of Powder Metallurgy 262
Summary 264
Key Terms 264
Bibliography 265
Review Questions 265
Qualitative Problems 265
Quantitative Problems 266
Synthesis, Design, and Projects 266
9Rapid -Prototyping Processes and Operations 267
9.1 Introduction 267
9.2 Subtractive Processes 270
9.3 Additive Processes 272
9.4 Virtual Prototyping 283
9.5 Direct Manufacturing and Rapid Tooling 284
Summary 291
Key Terms 291
Bibliography 291
Review Questions 292
Qualitative Problems 292
Quantitative Problems 292
Synthesis, Design, and Projects 293
Joining Processes and Equipment 295
10Fusion-Welding Processes 299
10.1 Introduction 299
10.2 Oxyfuel-gas Welding 300
10.3 Arc-welding Processes: Nonconsumable Electrode 303
10.4 Arc-welding Processes: Consumable Electrode 307
10.5 Electrodes for Arc Welding 313
10.6 Electron-beam Welding 314
10.7 Laser-beam Welding 314
10.8 Cutting 316
10.9 The Weld Joint, Quality, and Testing 318
10.10 Joint Design and Process Selection 327
Summary 327
Key Terms 327
Bibliography 332
Review Questions 332
Qualitative Problems 332
Quantitative Problems 333
Synthesis, Design, and Projects 333
11Solid-State Welding Processes 334
11.1 Introduction 334
11.2 Cold Welding and Roll Bonding 335
11.3 Ultrasonic Welding 336
11.4 Friction Welding 337
11.5 Resistance Welding 339
11.6 Explosion Welding 347
11.7 Diffusion Bonding 348
11.8 Economics of Welding Operations 350
Summary 352
Key Terms 353
Bibliography 353
Review Questions 353
Qualitative Problems 353
Quantitative Problems 354
Synthesis, Design, and Projects 354
12Brazing, Soldering, Adhesive-Bonding,and Mechanical-Fastening Processes 355
12.1 Introduction 355
12.2 Brazing 356
12.3 Soldering 360
12.4 Adhesive Bonding 365
12.5 Mechanical Fastening 373
12.6 Joining Plastics, Ceramics, and Glasses 376
12.7 Economics of Joining Operations 379
Summary 380
Key Terms 381
Bibliography 381
Review Questions 381
Qualitative Problems 382
Quantitative Problems 382
Synthesis, Design, and Projects 382