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• Cover
• Acronyms
• Title Page
• Preface
• History of the Text
• Purpose of the Book
• Organization of the Book
• Supplements
• Acknowledgments
• About the Authors
• CHAPTER 1: Introduction to DeGarmo’s Materials and Processes in Manufacturing
• 1.1 Materials, Manufacturing, and the Standard of Living
• 1.2 Manufacturing and Production Systems
• Review Questions
• Problems
• Chapter 1 CASE STUDY Famous Manufacturing Engineers
• Key Words
• CHAPTER 2: Properties of Materials
• 2.1 Introduction
• 2.2 Static Properties
• 2.3 Dynamic Properties
• 2.4 Temperature Effects (Both High and Low)
• 2.5 Machinability, Formability, and Weldability
• 2.6 Fracture Toughness and the Fracture Mechanics Approach
• 2.7 Physical Properties
• 2.8 Testing Standards and Testing Concerns
• Review Questions
• Problems
• Chapter 2 CASE STUDY Separation of Mixed Materials
• Key Words
• CHAPTER 3: Nature of Materials
• 3.1 Structure—Property—Processing—Performance Relationships
• 3.2 The Structure of Atoms
• 3.3 Atomic Bonding
• 3.4 Secondary Bonds
• 3.5 Atom Arrangements in Materials
• 3.6 Crystal Structures
• 3.7 Development of a Grain Structure
• 3.8 Elastic Deformation
• 3.9 Plastic Deformation
• 3.10 Dislocation Theory of Slippage
• 3.11 Strain Hardening or Work Hardening
• 3.12 Plastic Deformation in Polycrystalline Material
• 3.13 Grain Shape and Anisotropic Properties
• 3.14 Fracture
• 3.15 Cold Working, Recrystallization, and Hot Working
• 3.16 Grain Growth
• 3.17 Alloys and Alloy Types
• 3.18 Atomic Structure and Electrical Properties
• Review Questions
• Problems
• Key Words
• CHAPTER 4: Equilibrium Phase Diagrams and the Iron–Carbon System
• 4.1 Introduction
• 4.2 Phases
• 4.3 Equilibrium Phase Diagrams
• 4.4 Iron–Carbon Equilibrium Diagram
• 4.5 Steels and the Simplified Iron–Carbon Diagram
• 4.6 Cast Irons
• Review Questions
• Problems
• Chapter 4 CASE STUDY Fishhooks
• Key Words
• CHAPTER 5: Heat Treatment
• 5.1 Introduction
• 5.2 Processing Heat Treatments
• 5.3 Heat Treatments Used to Increase Strength
• 5.4 Strengthening Heat Treatments for Nonferrous Metals
• 5.5 Strengthening Heat Treatments for Steel
• 5.6 Surface Hardening of Steel
• 5.7 Furnaces
• 5.8 Heat Treatment and Energy
• Review Questions
• Problems
• Chapter 5 CASE STUDY A Carpenter’s Claw Hammer
• Key Words
• CHAPTER 6: Ferrous Metals and Alloys
• 6.1 Introduction to History-Dependent Materials
• 6.2 Ferrous Metals
• 6.3 Iron
• 6.4 Steel
• 6.5 Stainless Steels
• 6.6 Tool Steels
• 6.7 Cast Irons
• 6.8 Cast Steels
• 6.9 The Role of Processing on Cast Properties
• Review Questions
• Problems
• Chapter 6 CASE STUDY The Paper Clip
• Key Words
• CHAPTER 7: Nonferrous Metals and Alloys
• 7.1 Introduction
• 7.2 Copper and Copper Alloys
• 7.3 Aluminum and Aluminum Alloys
• 7.4 Magnesium and Magnesium Alloys
• 7.5 Zinc and Zinc Alloys
• 7.6 Titanium and Titanium Alloys
• 7.7 Nickel-Based Alloys
• 7.8 Superalloys, Refractory Metals, and Other Materials Designed for High-Temperature Service
• 7.9 Lead and Tin and Their Alloys
• 7.10 Some Lesser-Known Metals and Alloys
• 7.11 Metallic Glasses
• 7.12 Graphite
• 7.13 Materials for Specific Applications
• 7.14 High Entropy Alloys
• Review Questions
• Problems
• Chapter 7 CASE STUDY Hip Replacement Prosthetics
• Key Words
• CHAPTER 8: Nonmetallic Materials: Plastics,* Elastomers,** Ceramics, and Composites
• 8.1 Introduction
• 8.2 Plastics
• 8.3 Elastomers
• 8.4 Ceramics
• 8.5 Composite Materials
• Review Questions
• Problems
• Chapter 8 CASE STUDY Lightweight Armor and Protective Helmets
• Key Words
• CHAPTER 9: Material Selection
• 9.1 Introduction
• 9.2 Material Selection and Manufacturing Processes
• 9.3 The Design Process
• 9.4 Approaches to Material Selection
• 9.5 Additional Factors to Consider
• 9.6 Consideration of the Manufacturing Process
• 9.7 Ultimate Objective
• 9.8 Materials Substitution
• 9.9 Effect of Product Liability on Materials Selection
• 9.10 Aids to Material Selection
• Review Questions
• Problems
• Chapter 9 CASE STUDY Material Selection
• Key Words
• CHAPTER 10: Fundamentals of Casting
• 10.1 Introduction to Materials Processing
• 10.2 Introduction to Casting
• 10.3 Casting Terminology
• 10.4 The Solidification Process
• 10.5 Patterns
• 10.6 Design Considerations in Castings
• 10.7 The Casting Industry
• Review Questions
• Problems
• Chapter 10 CASE STUDY The Cast Oil-Field Fitting
• Key Words
• CHAPTER 11: Expendable-Mold Casting Processes
• 11.1 Introduction
• 11.2 Sand Casting
• 11.3 Cores and Core Making
• 11.4 Other Expendable-Mold Processes with Multiple-Use Patterns
• 11.5 Expendable-Mold Processes Using Single-Use Patterns
• 11.6 Shakeout, Cleaning, and Finishing
• 11.7 Summary
• Review Questions
• Problems
• Chapter 11 CASE STUDY Trailer Hitch Component
• Key Words
• CHAPTER 12: Multiple-Use-Mold Casting Processes
• 12.1 Introduction
• 12.2 Permanent-Mold Casting
• 12.3 Die Casting
• 12.4 Squeeze Casting and Semisolid Casting
• 12.5 Centrifugal Casting
• 12.6 Continuous Casting
• 12.7 Melting
• 12.8 Pouring Practice
• 12.9 Cleaning, Finishing, Heat Treating, and Inspection
• 12.10 Automation in Foundry Operations
• 12.11 Process Selection
• Review Questions
• Problems
• Chapter 12 CASE STUDY Baseplate for a Household Steam Iron
• Key Words
• CHAPTER 13: Fabrication of Plastics, Ceramics, and Composites
• 13.1 Introduction
• 13.2 Fabrication of Plastics
• 13.3 Processing of Rubber and Elastomers
• 13.4 Processing of Ceramics
• 13.5 Fabrication of Composite Materials
• Review Questions
• Problems
• Chapter 13 CASE STUDY Automotive and Light Truck Fuel Tanks
• Key Words
• CHAPTER 14: Fundamentals of Metal Forming
• 14.1 Introduction
• 14.2 Forming Processes: Independent Variables
• 14.3 Dependent Variables
• 14.4 Independent–Dependent Relationships
• 14.5 Process Modeling
• 14.6 General Parameters
• 14.7 Friction, Lubrication, and Wear under Metalworking Conditions
• 14.8 Temperature Concerns
• 14.9 Formability
• Review Questions
• Problems
• Chapter 14 CASE STUDY Interior Tub of a Top-Loading Washing Machine
• Key Words
• CHAPTER 15: Bulk Forming Processes
• 15.1 Introduction
• 15.2 Classification of Deformation Processes
• 15.3 Bulk Deformation Processes
• 15.4 Rolling
• 15.5 Forging
• 15.6 Extrusion
• 15.7 Wire, Rod, and Tube Drawing
• 15.8 Cold Forming, Cold Forging, and Impact Extrusion
• 15.9 Piercing
• 15.10 Other Squeezing Processes
• 15.11 Surface Improvement by Deformation Processing
• Review Questions
• Problems
• Chapter 15 CASE STUDY Automotive Engine Connecting Rod
• Key Words
• CHAPTER 16: Sheet-Forming Processes
• 16.1 Introduction
• 16.2 Shearing Operations
• 16.3 Bending
• 16.4 Drawing and Stretching Processes
• 16.5 Alternative Methods of Producing Sheet-Type Products
• 16.6 Seamed Pipe Manufacture
• 16.7 Presses
• Review Questions
• Problems
• Chapter 16 CASE STUDY Automotive Body Panels
• Key Words
• CHAPTER 17: Powder Metallurgy (Particulate Processing)
• 17.1 Introduction
• 17.2 The Basic Process
• 17.3 Powder Manufacture
• 17.4 Powder Testing and Evaluation
• 17.5 Powder Mixing and Blending
• 17.6 Compacting
• 17.7 Sintering
• 17.8 Advances in Sintering (Shorter Time, Higher Density, Stronger Products)
• 17.9 Hot-Isostatic Pressing
• 17.10 Other Techniques to Produce High-Density P/M Products
• 17.11 Metal Injection Molding (MIM)
• 17.12 Secondary Operations
• 17.13 Properties of P/M Products
• 17.14 Design of Powder Metallurgy Parts
• 17.15 Powder Metallurgy Products
• 17.16 Advantages and Disadvantages of Powder Metallurgy
• 17.17 Process Summary
• Review Questions
• Problems
• Chapter 17 CASE STUDY Steering Gear for a Riding Lawn Mower / Garden Tractor
• Key Words
• CHAPTER 18: Additive Processes—Including 3-D Printing
• 18.1 Introduction
• 18.2 Layerwise Manufacturing
• 18.3 Liquid-Based Processes
• 18.4 Powder-Based Processes
• 18.5 Deposition-Based Processes
• 18.6 Uses and Applications
• 18.7 Pros, Cons and Current and Future Trends
• 18.8 Economic Considerations
• Review Questions
• Problems
• Chapter 18 CASE STUDY Golf Club—Irons and Metal “Woods” via Additive Manufacturing
• Key Words
• CHAPTER 19: Fundamentals of Machining/Orthogonal Machining
• 19.1 Introduction
• 19.2 Fundamentals
• 19.3 Forces and Power in Machining
• 19.4 Orthogonal Machining (Two Forces)
• 19.5 Chip Thickness Ratio, rc
• 19.6 Mechanics of Machining (Statics)
• 19.7 Shear Strain, γ, and Shear Front Angle, ϕ
• 19.8 Mechanics of Machining (Dynamics) (Section courtsey of Dr. Elliot Stern)
• Summary
• Review Questions
• Problems
• Chapter 19 CASE STUDY Orthogonal Plate Machining Experiment at Auburn University
• Key Words
• CHAPTER 20: Cutting Tool Materials
• 20.1 Introduction
• 20.2 Cutting Tool Materials
• 20.3 Tool Geometry
• 20.4 Tool-Coating Processes
• 20.5 Tool Failure and Tool Life
• 20.6 Taylor Tool Life
• 20.7 Cutting Fluids
• 20.8 Economics of Machining
• Review Questions
• Problems
• Chapter 20 CASE STUDY Comparing Tool Materials Based on Tool life
• Key Words
• CHAPTER 21: Turning and Boring Processes
• 21.1 Introduction
• 21.2 Fundamentals of Turning, Boring, and Facing Turning
• 21.3 Lathe Design and Terminology
• 21.4 Cutting Tools for Lathes
• 21.5 Workholding in Lathes
• Review Questions
• Problems
• Chapter 21 CASE STUDY 1 Estimating the Machining Time for Turning
• Key Words
• CHAPTER 22: Milling
• 22.1 Introduction
• 22.2 Fundamentals of Milling Processes
• 22.3 Milling Tools and Cutters
• 22.4 Machines for Milling
• Review Questions
• Problems
• Chapter 22 CASE STUDY HSS vs. Tungsten Carbide Milling
• Key Words
• CHAPTER 23: Drilling and Related Hole-Making Processes
• 23.1 Introduction
• 23.2 Fundamentals of the Drilling Process
• 23.3 Types of Drills
• 23.4 Tool Holders for Drills
• 23.5 Workholding for Drilling
• 23.6 Machine Tools for Drilling
• 23.7 Cutting Fluids for Drilling
• 23.8 Counterboring, Countersinking, and Spot Facing
• 23.9 Reaming
• Review Questions
• Problems
• Chapter 23 Case Study Bolt-down Leg on a Casting
• Key Words
• CHAPTER 24: Sawing, Broaching, Shaping, and Filing Machining Processes
• 24.1 Introduction
• 24.2 Introduction to Sawing
• 24.3 Introduction to Broaching
• 24.4 Fundamentals of Broaching
• 24.5 Broaching Machines
• 24.6 Introduction to Shaping and Planing
• 24.7 Introduction to Filing
• Review Questions
• Problems
• Chapter 24 CASE STUDY Three Case Studies on Cost Estimating
• Key Words
• CHAPTER 25: Abrasive Machining Processes
• 25.1 Introduction
• 25.2 Abrasives
• 25.3 Grinding Wheel Structure and Grade
• 25.4 Grinding Wheel Identification
• 25.5 Grinding Machines
• 25.6 Honing
• 25.7 Superfinishing
• 25.8 Free Abrasives
• 25.9 Design Considerations in Grinding
• Review Questions
• Problems
• Chapter 25 CASE STUDY Process Planning for the MfE
• Key Words
• CHAPTER 26: CNC Processes and Adaptive Control: A(4) and A(5) Levels of Automation
• 26.1 Introduction
• 26.2 Basic Principles of Numerical Control
• 26.3 CNC Part Programming
• 26.4 Interpolation and Adaptive Control
• 26.5 Machining Center Features and Trends
• 26.6 Summary
• Review Questions
• Problems
• Key Words
• CHAPTER 27: JIG and Fixture Design
• 27.1 Introduction
• 27.2 Conventional Fixture Design
• 27.3 Tool Design Steps
• 27.4 Clamping Considerations
• 27.5 Chip Disposal
• 27.6 Example of Jig Design
• 27.7 Types of Jigs
• 27.8 Conventional Fixtures
• 27.9 Modular Fixturing
• 27.10 Setup and Changeover
• 27.11 Clamps
• 27.12 Other Workholding Devices
• 27.13 Economic Justification of Jigs and Fixtures
• Review Questions
• Problems
• Key Words
• CHAPTER 28: Nontraditional Manufacturing Processes
• 28.1 Introduction
• 28.2 Chemical Machining Processes
• 28.3 Electrochemical Machining Processes
• 28.4 Electrical Discharge Machining
• Review Questions
• Chapter 28 CASE STUDY Vented Cap Screws
• Key Words
• CHAPTER 29: Fundamentals of Joining
• 29.1 Introduction to Consolidation Processes
• 29.2 Classification of Welding and Thermal Cutting Processes
• 29.3 Some Common Concerns
• 29.4 Types of Fusion Welds and Types of Joints
• 29.5 Design Considerations
• 29.6 Heat Effects
• 29.7 Weldability or Joinability
• 29.8 Summary
• Review Questions
• Problems
• Key Words
• CHAPTER 30: Gas Flame and Arc Processes
• 30.1 Oxyfuel-Gas Welding
• 30.2 Oxygen Torch Cutting
• 30.3 Flame Straightening
• 30.4 Arc Welding
• 30.5 Consumable-Electrode Arc Welding
• 30.6 Nonconsumable Electrode Arc Welding
• 30.7 Other Processes Involving Arcs
• 30.8 Arc Cutting
• 30.9 Metallurgical and Heat Effects in Thermal Cutting
• 30.10 Welding Equipment
• 30.11 Thermal Deburring
• Review Questions
• Problems
• Chapter 30 CASE STUDY Bicycle Frame Construction and Repair
• Key Words
• CHAPTER 31: Resistance and Solid-State Welding Processes
• 31.1 Introduction
• 31.2 Theory of Resistance Welding
• 31.3 Resistance Welding Processes
• 31.4 Advantages and Limitations of Resistance Welding
• 31.5 Solid-State Welding Processes
• Review Questions
• Problems
• Chapter 31 CASE STUDY Manufacture of an Automobile Muffler
• Key Words
• CHAPTER 32: Other Welding Processes, Brazing, and Soldering
• 32.1 Introduction
• 32.2 Other Welding and Cutting Processes
• 32.3 Surface Modification by Welding-Related Processes
• 32.4 Brazing
• 32.5 Soldering
• Review Questions
• Problems
• Chapter 32 CASE STUDY Impeller of a Pharmaceutical Company Industrial Shredder/Disposal
• Key Words
• CHAPTER 33: Adhesive Bonding, Mechanical Fastening, and Joining of Non-Metals
• 33.1 Adhesive Bonding
• 33.2 Mechanical Fastening
• 33.3 Joining of Plastics
• 33.4 Joining of Ceramics and Glass
• 33.5 Joining of Composites
• Review Questions
• Problems
• Chapter 33 CASE STUDY Golf Club Heads with Insert
• Key Words
• CHAPTER 34: Surface Integrity and Finishing Processes
• 34.1 Introduction
• 34.2 Surface Integrity
• 34.3 Abrasive Cleaning and Finishing
• 34.4 Chemical Cleaning
• 34.5 Coatings
• 34.6 Vaporized Metal Coatings
• 34.7 Clad Materials
• 34.8 Textured Surfaces
• 34.9 Coil-Coated Sheets
• 34.10 Edge Finishing and Burr Removal
• Review Questions
• Chapter 34 CASE STUDY Dana Lynn’s Fatigue Lesson
• Key Words
• CHAPTER 35: Nano and Micro-Manufacturing Processes
• 35.1 Introduction
• 35.2 Lithography
• 35.3 Micromachining Processes
• 35.4 Deposition Processes
• 35.5 How ICs are Made
• 35.6 Nano- and Micro-Scale Metrology
• Review Questions
• Problems
• CHAPTER 36: Measurement and Inspection
• 36.1 Introduction
• 36.2 Standards of Measurement
• 36.3 Allowance and Tolerance
• 36.4 Inspection Methods for Measurement
• 36.5 Measuring Instruments
• 36.6 Vision Systems
• 36.7 Coordinate Measuring Machines
• 36.8 Angle-measuring Instruments
• 36.9 Gages for Attributes Measuring
• Review Questions
• Problems
• Chapter 36 CASE STUDY Measuring an Angle
• Key Words
• CHAPTER 37: Nondestructive Examination (NDE) / Nondestructive Testing (NDT)
• 37.1 Destructive vs. Nondestructive Testing
• 37.2 Visual Inspection
• 37.3 Liquid Penetrant Inspection
• 37.4 Magnetic Particle Inspection
• 37.5 Ultrasonic Inspection
• 37.6 Radiography
• 37.7 Eddy-Current Testing
• 37.8 Acoustic Emission Monitoring
• 37.9 Other Methods of Nondestructive Testing and Inspection
• 37.10 Dormant vs. Critical Flaws
• 37.11 Current and Future Trends
• Review Questions
• Problems
• Chapter 37 CASE STUDY Portable Failure Analysis Kit
• Key Words
• CHAPTER 38: Manufacturing Automation and Industrial Robots
• 38.1 Introduction
• 38.2 The A(4) Level of Automation
• 38.3 A(5) Level of Automation Requires Evaluation
• 38.4 Industrial Robotics
• 38.5 Computer-Integrated Manufacturing (CIM)
• 38.6 Computer-Aided Design
• 38.7 Computer-Aided Manufacturing
• 38.8 Summary
• Review Questions
• Key Words
• ADVANCED TOPIC 1: Process Capability and Quality Control
• A1.1 Introduction
• A1.2 Determining Process Capability
• A1.3 Introduction to Statistical Quality Control
• A1.4 Sampling Errors
• A1.5 Gage Capability
• A1.6 Just in Time/Total Quality Control
• A1.7 Six Sigma
• A1.8  Summary
• Review Questions
• Problems
• CASE STUDY QC Chart Blunders
• Key Words
• ADVANCED TOPIC 2: The Enterprise (Production System)
• A2.1 Introduction
• A2.2 Typical Functional Areas in the Production System (PS)
• Review Questions
• Problems
• Key Words
• ADVANCED TOPIC 3: Lean Engineering
• A3.1 Introduction
• A3.2 The Lean Engineer
• A3.3 The Lean Production System
• A3.4 Linked-Cell Manufacturing System Design Rules
• A3.5 Manufacturing System Designs
• A3.6 Preliminary Steps to Lean Production
• A3.7 Methodology for Implementation of Lean Production
• A3.8 Design Rule MT < CT
• A3.9 Decouplers
• A3.10 Integrating Production Control
• A3.11 Integrating Inventory Control
• A3.12 Lean Manufacturing Cell Design
• A3.13 Machine Tool Design for Lean Manufacturing Cells
• A3.14 L-CMS Strategy
• Review Questions
• Problems
• ADVANCED TOPIC 3 CASE STUDY Cycle Time for a Manufacturing Cell
• Key Words
• ADVANCED TOPIC 4: Mixed-Model Final Assembly
• A4.1 Introduction
• A4.2 History
• A4.3 Mixed-Model Final Assembly
• A4.4 An Example of MMFA
• A4.5 Key Enabling Systems
• A4.6 Manual Assembly Line Balancing
• A4.7 Sequencing
• A4.8 Quality in Mixed-Model Final Assembly
• A4.9 Examples of Assembly Aids/Poka-Yoke (Error-Proofing) Applications
• A4.10 Summary
• Review Questions
• Problems
• Index
• Selected References for Additional Study
• End User License Agreement