Manufacturing Technology: Materials, Processes, and Equipment

Cover
Half Title
Title Page
Copyright Page
Dedication
Table of Contents
Preface
Acknowledgments
Authors
List of Acronyms
List of Symbols
Greek Letters
Chapter 1: Introduction to Manufacturing Technology
1.1 Importance of Manufacturing Technology
1.2 Selection of Materials and Manufacturing Processes
1.2.1 Selection of Materials for Manufacturing
1.2.2 Selection of Manufacturing Processes
1.2.3 Classification of Manufacturing Processes
1.2.3.1 Smelting and Casting Processes
1.2.3.2 Plastic Forming Processes for Metallic Materials
1.2.3.3 Powder Metallurgy and Ceramic Processing
1.2.3.4 Machining Processes
1.2.3.5 Joining Processes
1.2.3.6 Surface Treatment Processes
1.2.3.7 Heat Treatment Processes
1.2.3.8 Assembly
1.2.3.9 Additive Manufacturing Processes
1.2.3.10 Modern Manufacturing Processes
1.2.3.11 Complementary Processes
1.3 Company Organization
1.4 Role of Computers in Modern Manufacturing Technology
1.5 Planning for Manufacturing
1.6 Accuracy of Manufacturing Processes
1.7 Economical and Environmental Considerations
1.8 Health and Safety Aspects
Review Questions
Bibliography
Chapter 2: Properties of Engineering Materials
2.1 Introduction
2.2 Physical Properties
2.2.1 Density
2.2.2 Thermal Properties
2.2.3 Electrical and Magnetic Properties
2.2.4 Optical Properties
2.2.5 Chemical and Corrosion Properties
2.3 Mechanical Properties
2.3.1 Strength
2.3.2 Ductility and Brittleness
2.3.3 Toughness
2.3.4 Hardness
2.3.5 Fatigue
2.3.6 Creep
2.4 Manufacturing (Fabricating) Properties
2.4.1 Castability
2.4.2 Ductility, Malleability, Workability, and Formability
2.4.3 Machinability
2.4.4 Grindability
2.4.5 Weldability
2.4.6 Heat Treatability
Review Questions
Problems
Bibliography
Chapter 3: Structure of Metals and Alloys
3.1 Introduction
3.2 Lattice Structure of Metals
3.2.1 Space Lattices
3.2.2 Allotropic (Polymorphic) Crystals (Changes in Crystal Structure)
3.2.3 Effect of Lattice Structure on Density of Metals
3.3 Imperfections in Lattice Structure
3.3.1 Point Defects
3.3.2 Line Defects (Dislocations)
3.3.3 Surface or Planar Defects (Grain Boundaries)
3.3.4 Volume or Bulk Defects
3.4 Solidification of Metals and Alloys
3.4.1 Solidification of Pure Metals and Alloys
3.4.2 Solid Solutions
3.4.3 Phase Diagrams
3.4.4 Iron–Carbon Phase Diagram
Review Questions
Problems
Bibliography
Chapter 4: Engineering Materials and Their Applications
4.1 Introduction
4.2 Classification of Engineering Materials
4.3 Ferrous Metals and Alloys
4.3.1 Steels and Steel Alloys
4.3.1.1 Steel Designation
4.3.1.2 Steels and Typical Applications
4.3.2 Cast Irons
4.3.2.1 General Characteristics
4.3.2.2 Common Types of Cast Irons
4.4 Nonferrous Metals and Alloys
4.4.1 Aluminum and Aluminum Alloys
4.4.2 Magnesium and Magnesium Alloys
4.4.3 Zinc and Zinc Alloys
4.4.4 Lead, Tin, and Lead–Tin Alloys (White Metals)
4.4.5 Copper and Copper Alloys
4.4.6 Nickel and Nickel Alloys
4.4.7 Titanium and Titanium Alloys
4.4.8 Superalloys
4.4.9 Refractory Metals
4.4.10 Noble Metals
4.5 Newly Born Engineering Materials
4.5.1 Nanomaterials
4.5.2 Amorphous Alloys
4.5.3 Metal Foams
4.5.4 Shape Memory Alloys
Review Questions
Bibliography
Chapter 5: Heat Treatment of Metals and Alloys
5.1 Introduction
5.2 Heat Treatment of Steels
5.2.1 Simplified Iron-Iron Carbide Equilibrium Diagram
5.2.2 Effect of Alloying Elements
5.2.3 Time–Temperature–Transformation Diagram (T–T–T Diagram)
5.3 Basic Heat Treatment Operations of Steels
5.3.1 Annealing Processes
5.3.2 Normalizing
5.3.3 Tempering
5.3.4 Anticrack Hardening Techniques
5.3.4.1 Austempering (Isothermal Quenching)
5.3.4.2 Martempering (Interrupted or Marquenching)
5.3.5 Full-Depth Hardening (through Hardening)
5.3.6 Surface Hardening Techniques
5.3.6.1 Methods of Selective Hardening
5.3.6.2 Diffusion Methods (Thermochemical Hardening)
5.4 Heat Treatment of Cast Iron
5.5 Heat Treatment of Nonferrous Alloys and Stainless Steels (Precipitation Hardening)
Review Questions
Bibliography
Chapter 6: Smelting of Metallic Materials
6.1 Introduction
6.2 Smelting of Ferrous Metals
6.2.1 Blast Furnace
6.2.2 Steel Refining Processes
6.2.2.1 Basic Oxygen Converter (L-D Process)
6.2.2.2 Electric Arc Furnace
6.2.2.3 Induction Furnaces
6.2.2.4 Ingot Casting
6.2.2.5 Continuous Casting
6.2.3 Cast Iron Refining: Cupola Furnace
6.3 Smelting and Extraction of Nonferrous Metals
6.3.1 Aluminum
6.3.2 Copper
6.3.3 Titanium
6.3.4 Miscellaneous Metals
Review Questions
Bibliography
Chapter 7: Casting of Metallic Materials
7.1 Introduction and Classification
7.2 Historical Development of Casting
7.3 Expendable Mold Casting Processes
7.3.1 Sand Casting
7.3.1.1 Patterns
7.3.1.2 Cores
7.3.1.3 Gating System
7.3.1.4 Types of Sand Molds
7.3.1.5 Sand Molding Techniques
7.3.2 Shell Molding
7.3.3 Vacuum Molding
7.3.4 Slurry Molding
7.3.5 Plaster Molding
7.3.6 Ceramic Molding
7.3.7 Expendable Mold, Expendable Pattern Casting
7.3.7.1 Investment Casting (Lost-Wax Process)
7.3.7.2 Evaporative Casting (Lost-Foam Process)
7.4 Permanent Mold Castings
7.4.1 Die Casting Processes
7.4.1.1 Gravity Die Casting
7.4.1.2 Slush Casting
7.4.1.3 Low-Pressure Die Casting
7.4.1.4 Vacuum Die Casting
7.4.1.5 Pressure Die Casting
7.4.2 Centrifugal Casting
7.4.2.1 True Centrifugal Casting
7.4.2.2 Semi-Centrifugal Casting
7.4.2.3 Centrifuging (Centrifuged Casting)
7.5 Melting Furnaces
7.5.1 Cupolas
7.5.2 Crucible Furnace
7.6 Cleaning and Finishing of Castings
7.7 Quality of Castings
7.8 Modeling of Casting
7.8.1 Fluidity
7.8.2 Fluid Flow through the Gating System
7.8.3 Mold Filling Time
7.8.4 Solidification Time
7.9 Impact of Recent Developments in Materials on Casting Technology
7.9.1 Casting of Composites
7.9.2 Casting of Functionally Graded Materials
7.9.3 Casting of Porous (Foam) Metals
Review Questions
Problems
Bibliography
Chapter 8: Fundamentals of Metal Forming
8.1 Introduction
8.2 Simple Stresses and Strains
8.2.1 Elastic Stresses and Strains
8.2.2 Plastic Stresses and Strains
8.2.2.1 Poisson’s Ratio
8.2.3 True Stress and True Strain
8.2.4 Empirical Relations for the Stress–Strain Curve
8.2.4.1 Idealized Stress–Strain Curves
8.3 Two- and Three-Dimensional Stresses and Strains
8.3.1 Principal Stresses and Strains
8.3.1.1 Mean (Hydrostatic) Stress and Stress Deviators
8.3.1.2 Principal Strains
8.3.2 General Stress–Strain Relations in the Elastic Range
8.3.3 Some Special Conditions of Stress and Strain
8.4 Yield Criteria
8.5 General Plastic Stress–Strain Relations (Theory of Plasticity)
8.5.1 Plastic Work
8.6 Effect of Temperature on Plastic Deformation
8.7 Cold, Warm, and Hot Forming
8.7.1 Cold Forming
8.7.2 Warm Forming
8.7.3 Hot Forming
8.8 Effect of Strain Rate on Plastic Deformation
8.9 Superplasticity
8.10 Effect of Friction and Lubrication in Metal Forming
Review Questions
Problems
Bibliography
Chapter 9: Bulk Forming of Metallic Materials
9.1 Introduction
9.2 Classification of Forming Processes
9.3 Forging Processes
9.3.1 Open-Die Forging
9.3.2 Close-Die (Impression) Forging
9.3.3 Special Forging Processes
9.3.3.1 Rotary Swaging
9.3.3.2 Radial Forging
9.3.3.3 Orbital Forging
9.3.3.4 Coining
9.3.4 Forging Equipment
9.3.4.1 Mechanical Presses
9.3.4.2 Hydraulic Presses
9.3.4.3 Hammers
9.3.5 Forging Defects
9.3.6 Modeling of Forging Processes
9.3.6.1 Direct Compression (Upsetting) in Plane Strain
9.3.6.2 Upsetting a Solid Cylindrical Specimen
9.3.6.3 Modeling of Impression-Die Forging
9.4 Rolling Processes
9.4.1 Flat Rolling
9.4.2 Section Rolling
9.4.3 Tube Rolling
9.4.3.1 Rotary Piercing (Mannesmann Process)
9.4.3.2 Three-Roll Rotary Piercing
9.4.3.3 The Pilger Process
9.4.3.4 Rolling of Seamed Tubes
9.4.4 Special Rolling Processes
9.4.5 Rolling Defects
9.4.6 Modeling of Flat Rolling
9.4.7 Determination of the Neutral Point
9.5 Extrusion
9.5.1 Classification of Extrusion Processes
9.5.1.1 Direct and Indirect Extrusion
9.5.1.2 Hydrostatic Extrusion
9.5.1.3 Tube Extrusion
9.5.1.4 Porthole Die Extrusion
9.5.1.5 Cold Extrusion and Impact Extrusion
9.5.1.6 Conform Extrusion
9.5.2 Extrusion Equipment
9.5.3 Extrusion Defects
9.5.4 Modeling of Direct Extrusion
9.6 Rod, Wire, and Tube Drawing
9.6.1 Classification of Drawing Processes
9.6.1.1 Rod Drawing
9.6.1.2 Wire Drawing
9.6.1.3 Tube Drawing
9.6.2 The Drawing Die
9.6.3 Modeling of the Drawing Process
Review Questions
Problems
Bibliography
Chapter 10: Sheet Metal Forming Processes
10.1 Introduction and Classification
10.2 Shearing Processes
10.2.1 Classification of Shearing Processes
10.2.1.1 Open Contour Shearing
10.2.1.2 Closed Contour Shearing
10.2.2 Shearing Mechanism
10.3 Bending Processes
10.3.1 Bending Parameters
10.3.2 Springback in Bending
10.3.3 Residual Stresses in Bending
10.3.4 Bending Equipment
10.3.4.1 Press Brake
10.3.4.2 Roll Bending Machines
10.3.4.3 Contour Roll Forming
10.4 Stretch Forming
10.4.1 Stretch Forming Machines and Accessories
10.5 Deep Drawing
10.5.1 Blank Holding Pressure
10.5.2 Ironing
10.5.3 Deep-Drawing Force
10.5.4 Limiting Drawing Ratio
10.5.5 Effect of Anisotropy
10.5.6 Redrawing
10.6 Rubber Pad Forming (Flexible-Die Forming)
10.6.1 Rubber Pad Forming Techniques
10.7 Hydroforming (Fluid-Forming Processes)
10.8 Spinning
10.8.1 Conventional Spinning
10.8.2 Flow Turning (Shear Spinning)
10.8.3 Tube Spinning
10.9 Superplastic Forming of Sheets
10.10 Blow Forming and Vacuum Forming
10.11 Thermoforming Methods
10.11.1 Superplastic Forming/Diffusion Bonding Process
10.12 Sheet Metal Formability
10.12.1 Testing for Formability
10.12.2 Forming Limit Diagrams
Review Questions
Problems
Bibliography
Chapter 11: High-Velocity Forming and High–Energy Rate Forming
11.1 Introduction and Classification
11.2 Characteristics of HVF and HERF Processes
11.3 High-Velocity Forming Machines
11.3.1 Pneumatic (Compressed Air) Hammer
11.3.2 Compressed Gas Forming Hammer
11.3.3 Gas Combustion High-Speed Hammers
11.4 High–Energy Rate Forming Processes
11.4.1 Explosive Forming
11.4.1.1 Principles and Types of Explosives
11.4.1.2 Classification of Explosive Forming Methods
11.4.1.3 Process Variables
11.4.1.4 Advantages and Limitations
11.4.2 Electromagnetic Forming
11.4.2.1 Principles of the Process
11.4.2.2 Basic Methods of Electromagnetic Forming
11.4.2.3 Pressure Required for EMF
11.4.2.4 Advantages and Limitations of EMF
11.4.2.5 Safety Considerations
11.4.3 Electrohydraulic Forming
11.4.3.1 Principles of the Process
11.4.3.2 Energy Requirements
11.4.3.3 Process Variables
11.4.3.4 Advantages and Limitations
11.4.4 Laser Forming
11.4.4.1 LASER Forming Mechanisms
11.4.4.2 LASER Forming Parameters
11.4.4.2.1 Laser Forming Strategies and Control
11.4.4.3 Laser Bending of Tubes
11.4.4.4 Industrial Applications of LASER Forming
11.5 Future of HVF and HERF
Review Questions
Problems
Bibliography
Chapter 12: Powder Metallurgy and Processing of Ceramic Materials
12.1 Introduction
12.2 Historical Development of Powder Metallurgy
12.3 Metal Powder Production
12.3.1 Thermal/Mechanical Methods
12.3.1.1 Atomization
12.3.1.2 Comminution
12.3.1.3 Mechanical Alloying
12.3.2 Chemical Methods
12.3.2.1 Reduction
12.3.2.2 Precipitation from Solution
12.3.2.3 Thermal Decomposition
12.3.3 Electrodeposition
12.4 Powder Metal Characterization
12.4.1 Particle Geometric Features
12.4.2 Interparticle Friction and Flow Characteristics
12.4.3 Density and Packing
12.4.4 Chemistry and Surface Films
12.5 Blending and Mixing of Powders
12.6 Powder Compaction
12.6.1 Conventional Compaction
12.6.2 Isostatic Compaction
12.6.3 Powder Injection Molding
12.6.4 Powder Rolling
12.6.5 Powder Extrusion
12.7 Sintering
12.8 Secondary Operations
12.9 Ceramic Materials
12.9.1 Traditional Ceramics
12.9.2 Glasses and Glass Ceramics
12.9.3 Advanced (Engineering) Ceramics
12.10 Ceramic Manufacturing Processes
12.10.1 Chemical Vapor Deposition
12.10.2 Directed Metal Oxidation
12.10.3 Reaction Bonding
12.10.4 Sol-Gel Processing
12.10.5 Polymer Pyrolysis
12.10.6 Melt Casting
12.10.7 Ceramic Processing using Powder Metallurgy
Review Questions
Bibliography
Chapter 13: Polymeric Materials and Their Processing
13.1 Introduction
13.2 Historical Development of Polymeric Materials
13.3 Polymerization
13.3.1 Polymerization Reactions
13.3.2 Degree of Polymerization and Molecular Weight
13.3.3 Forms of Polymer Chains
13.3.4 Copolymers
13.3.5 Crystallinity in Polymers
13.3.6 Glass Transition Temperature and Melting Point of Polymers
13.4 Thermoplastic Polymers (Thermoplastics, TP)
13.4.1 Thermomechanical Properties of Thermoplastics
13.4.2 Major Families of Thermoplastics
13.5 Thermosetting Polymers (Thermosets)
13.5.1 General Characteristics of Thermosets
13.5.2 Major Families of Thermosets
13.6 Elastomers
13.7 Thermoplastic Elastomers
13.8 Processing of Polymeric Materials
13.8.1 Extrusion
13.8.2 Calendering
13.8.3 Spinning of Fibers
13.8.4 Injection Molding
13.8.5 Blow Molding
13.8.6 Rotational Molding
13.8.7 Compression Molding
13.8.8 Transfer Molding
13.8.9 Thermoforming
13.8.10 Casting Processes
13.8.10.1 Casting of Thermoplastics
13.8.10.2 Casting of Thermosets
13.8.11 Foam Processing
13.8.12 Joining of Plastics
Review Questions
Problems
Bibliography
Chapter 14: Composite Materials and Their Fabrication Processes
14.1 Introduction
14.2 Classification and Characteristics of Composites
14.3 Fiber-Reinforced Composites
14.3.1 Fibers and Whiskers
14.3.2 Matrix Materials
14.4 Particulate Composite Materials
14.5 Laminated Composite Materials
14.5.1 Bimetals
14.5.2 Clad Metals
14.5.3 Sandwich and Honeycomb Structures
14.5.4 Laminate Glass
14.5.5 Polymeric-based Laminates
14.6 Combinations of Composite Materials
14.7 Fabrication of Composite Materials
14.8 Molding Processes
14.8.1 Contact Molding
14.8.2 Compression Molding
14.8.3 Vacuum Molding
14.8.4 Liquid Composite Molding
14.8.5 Molding by Foam Injection
14.8.6 Centrifugal Molding of Tubes
14.9 Prepreg Fabrication
14.10 Filament Winding
14.11 Pultrusion
Review Questions
Problems
Bibliography
Chapter 15: Fundamentals of Traditional Machining Processes
15.1 Introduction
15.2 Basics of Chipping Processes
15.2.1 Elements and Kinematics of a Chipping Process
15.2.2 Geometry of a Single-Edge Tool
15.2.2.1 Tool Angles
15.2.2.2 Tool Signature according to American Standard Association
15.2.3 Chip Formation–Characteristic Types of Chips–Chip Breakers
15.2.3.1 Chip Formation
15.2.3.2 Characteristic Types of Chips
15.2.3.2.1 Discontinuous Chips
15.2.3.2.2 Continuous Chips
15.2.3.2.3 Continuous Chips with BUE
15.2.3.3 Chip Breakers
15.2.4 Mechanics of the Chipping Process
15.2.4.1 Orthogonal Cutting
15.2.4.1.1 Merchant Analysis
15.2.4.1.2 Other Shear Angle Relationships
15.2.4.2 Oblique Cutting
15.2.4.2.1 Cutting Forces
15.2.4.2.2 Power Requirement
15.2.4.2.3 Specific Cutting Power and Specific Cutting Resistance
15.2.5 Cutting Tool Materials
15.2.5.1 Characteristics of Cutting Tool Materials
15.2.5.2 Types of Tool Materials
15.2.5.2.1 Tool Steels
15.2.5.2.2 High-Speed Steel
15.2.5.2.3 Cast Nonferrous Alloys
15.2.5.2.4 Cemented (Sintered) Carbides: Widia
15.2.5.2.5 Ceramics (Alumina-Base Tools)
15.2.5.2.6 Cermets
15.2.5.2.7 Diamond
15.2.5.2.8 Cubic Boron Nitride
15.2.5.2.9 Sialon
15.2.6 Tool Wear and Tool Life
15.2.6.1 Tool Wear
15.2.6.2 Tool Life
15.2.6.2.1 Tool Life Criteria
15.2.6.2.2 Taylor’s Tool Life Equation
15.2.7 Machining Economy
15.2.7.1 Minimum Cost Criterion
15.2.7.2 Minimum Machining Time Criterion
15.2.7.3 Comparison of the Two Criteria
15.2.8 Machinability
15.2.9 Cutting Fluids
15.2.10 Thermal Aspect in Metal Cutting
15.3 Basics of Abrasion Processes
15.3.1 Grinding
15.3.1.1 Grinding Wheels
15.3.1.1.1 Grinding Wheel Marking
15.3.1.2 Truing and Dressing, Balancing, and Safety Measures
15.3.1.2.1 Truing and Dressing of CWs
15.3.1.2.2 Balancing of CWs
15.3.1.2.3 Safety Measures When Grinding
15.3.1.3 Mechanics of the Grinding Operation
15.3.1.3.1 Forces and Power in Grinding
15.3.1.3.2 Calculation of the Main Cutting Force F c in Plunge-Cut Cylindrical Grinding
15.3.2 Honing
15.3.2.1 Stock Removal
15.3.2.2 Dimensional Accuracy and Surface Finish
15.3.3 Superfinishing (Microfinishing)
15.3.4 Lapping
Review Questions
Problems
Bibliography
Chapter 16: Machine Tools for Traditional Machining
16.1 Introduction
16.2 General Purpose Machine Tools
16.2.1 Machine Tools for Cutting Cylindrical Surfaces
16.2.1.1 Lathe Machines
16.2.1.2 Boring Machines
16.2.1.3 Drilling Machines
16.2.2 Machine Tools for Cutting Flat Surfaces
16.2.2.1 Shapers, Planers, and Slotters
16.2.2.2 Milling Machines
16.3 General Purpose Milling Machines
16.3.1 Broaching Machines
16.3.2 Grinding Machines
16.3.2.1 Surface Grinding Machines
16.3.2.2 Cylindrical Grinding Machines
16.3.3 Microfinishing Machines
16.3.3.1 Honing Machines
16.3.3.2 Superfinishing Machines
16.3.3.3 Lapping Machines
16.4 Special Purpose Machine Tools
16.4.1 Thread Cutting Machines
16.4.2 Gear Cutting Machines
Review Questions
Problems
Bibliography
Chapter 17: Fundamentals of Nontraditional Machining Processes
17.1 Introduction
17.2 Classification of Nontraditional Machining Processes
17.3 Jet Machining
17.3.1 Abrasive Jet Machining
17.3.2 Water Jet Machining
17.3.3 Abrasive Water Jet Machining
17.4 Ultrasonic Machining
17.4.1 USM Equipment
17.4.1.1 Oscillating System
17.4.1.2 Tool Feeding Mechanism and Slurry System
17.4.2 Process Capabilities
17.4.2.1 Material Removal Rate
17.4.2.2 Accuracy and Surface Quality
17.5 Chemical Machining
17.5.1 Chemical Milling
17.5.2 Photochemical Machining
17.6 Electrochemical Machining
17.6.1 Elements of the ECM Process
17.6.2 ECM Equipment
17.6.3 Process Capabilities
17.7 Electrochemical Grinding
17.8 Electric Discharge Machining
17.8.1 Electric Discharge Sinking (Conventional EDM)
17.8.1.1 Electric Discharge Sinking Machine
17.8.1.2 Dielectric Fluids
17.8.1.3 Spark Circuits
17.8.1.4 Tool Electrodes
17.8.1.5 Process Capabilities
17.8.2 Electrical Discharge Milling
17.8.3 Electric Discharge Wire Cutting
17.9 Electron Beam Machining
17.9.1 EBM Equipment
17.9.2 Process Capabilities
17.10 Laser Beam Machining
17.10.1 LBM Equipment
17.10.2 Applications and Capabilities
17.11 Plasma Arc Cutting
17.11.1 Plasma Arc Cutting Systems
17.11.2 Applications and Capabilities of PAC
17.12 Concluding Characteristics of NTMPs
Review Questions
Problems
Bibliography
Chapter 18: Numerical Control of Machine Tools
18.1 Introduction
18.1.1 Economics of CNC
18.1.2 Advantages of CNC
18.1.3 Disadvantages of CNC
18.1.4 NC System Components
18.2 NC Concepts
18.2.1 Machine Tool Axes
18.2.2 Point Location
18.2.3 Absolute and Incremental Positioning
18.3 Movements in CNC Systems
18.4 Control of NC Machine Tools
18.5 CNC Machine Tools
18.6 Input Units
18.7 CNC Instructions
18.8 Program Format
18.8.1 Fixed Block Format
18.8.2 TAB Sequential Format
18.8.3 Word Address Format
18.9 Features of CNC Systems
18.10 Part Programming
18.10.1 Manual Part Programming
18.10.2 Computer-Assisted Part Programming
18.10.3 CAD/CAM Part Programming
Review Questions
Problems
Bibliography
Chapter 19: Industrial Robots and Hexapods
19.1 Introduction
19.2 Industrial Robots
19.2.1 Robots and Robotics
19.2.2 Major Components of an Industrial Robot
19.2.3 Types of Robot Manipulators
19.2.4 Drive Systems (Actuators)
19.2.5 Controllers
19.2.6 Programming of Robots
19.2.7 Robot Characteristics
19.2.8 Applications of Industrial Robots in Manufacturing
19.2.9 Robot Economics
19.2.10 Recent and Future Developments of Industrial Robots
19.3 Hexapods
19.3.1 Historical Background
19.3.2 Hexapod Mechanism
19.3.3 Constructional Features of Hexapods
19.3.4 Manufacturing Applications of Hexapods
Review Questions
Problems
Bibliography
Chapter 20: Surface Technology
20.1 Introduction
20.2 Surface Smoothing
20.2.1 Mechanical Smoothing
20.2.2 Electropolishing
20.3 Surface Cleaning
20.3.1 Peen Cleaning
20.3.1.1 Shot Peening
20.3.1.2 Jet Peening
20.3.1.3 CO 2 –Ice–Pellet Peening
20.3.2 Barrel Tumbling and Vibratory Finishing
20.3.3 Ultrasonic Cleaning
20.3.4 Chemical Cleaning
20.4 Surface Protection
20.4.1 Sacrificial Protection (Cathodic or Galvanic Protection)
20.4.2 Direct Protection
20.4.2.1 Conversion Coatings (Chemical Reaction Priming)
20.4.2.2 Electroplating
20.4.2.3 Organic Coatings (Paints)
20.4.2.3.1 Important Fields of Application
20.4.2.3.2 Classification of Organic Coatings (Paints)
20.4.2.3.3 Preparation for Painting
20.4.2.3.4 Painting Methods
20.4.2.3.5 Baking (Drying and Curing)
20.4.2.4 Vitreous Coatings (Porcelain and Ceramic Enamels)
20.4.2.5 Vaporized Metal Coating (PVD and CVD)
20.4.2.5.1 Physical Vapor Deposition
20.4.2.5.2 Chemical Vapor Deposition
20.4.2.6 Metal Spraying (Metallizing)
20.4.2.7 Cladding (Clad or Diffusion Bonding)
20.5 Roll Burnishing and Ballizing
20.6 Deburring
Review Questions
Problems
Bibliography
Chapter 21: Joining Processes: Manufacturing Technology
21.1 Introduction
21.2 Fusion Welding
21.2.1 Gas Welding
21.2.1.1 Oxyacetylene Welding Equipment
21.2.1.2 Oxy-Gas Welding Techniques
21.2.1.2.1 Backhand (Rightward) Welding
21.2.1.2.2 Forehand (Leftward) Welding
21.2.2 Thermit Welding
21.2.3 Electric Arc Welding
21.2.3.1 Shielded Metal Arc Welding
21.2.3.2 Flux Cored Arc Welding
21.2.3.3 Gas Metal Arc Welding
21.2.3.4 Submerged Arc Welding
21.2.3.5 Underwater Welding
21.2.3.6 Electroslag Welding
21.2.3.7 Gas Tungsten Arc Welding
21.2.3.8 Atomic Hydrogen Welding
21.2.3.9 Carbon Arc Welding
21.2.3.10 Plasma Arc Welding
21.2.4 Resistance Welding
21.2.4.1 Resistance Spot Welding
21.2.4.2 Resistance Projection Welding
21.2.4.3 Resistance Seam Welding
21.2.4.4 Flash Welding
21.2.5 High-Energy Beam Welding
21.2.5.1 Electron Beam Welding
21.2.5.2 Laser Beam Welding
21.3 Solid-State Welding
21.3.1 Cold Welding
21.3.2 Diffusion Welding
21.3.3 Explosion Welding
21.3.4 Forge Welding
21.3.5 Friction Welding
21.3.6 Hot Pressure Welding
21.3.7 Roll Welding
21.3.8 Ultrasonic Welding
21.4 Solid–Liquid-State Welding
21.4.1 Brazing
21.4.2 Soldering
21.4.3 Adhesive Bonding
21.5 Welding of Plastics
21.6 Metallurgy of Welded Joints
21.7 Welding Defects
21.8 Welding Quality Control
21.8.1 Nondestructive Testing
21.8.2 Destructive Testing
21.9 Mechanical Joining
Review Questions
Problems
Bibliography
Chapter 22: Advanced Manufacturing Technology
22.1 Introduction
22.2 Microfabrication Technology
22.2.1 Microcutting Operations
22.2.2 Microfinishing Operations
22.2.3 Nonconventional Micromachining
22.3 Nanotechnology
22.3.1 Applications of Nanotechnology
22.4 Semiconductor Device Fabrication
22.4.1 Wafer Fabrication
22.4.2 Testing Assembly and Packaging
22.5 Sustainable and Green Manufacturing
Review Questions
Bibliography
Chapter 23: Additive Manufacturing
23.1 Introduction
23.2 AM versus Subtractive Processes: Advantages and Challenges
23.3 Additive Manufacturing Technologies
23.3.1 Vat Photopolymerization
23.3.1.1 Stereolithography
23.3.1.1.1 Time Estimation of SLA Process
23.3.1.1.2 Advantages and Limitations of SLA
23.3.1.1.3 Main Applications of Parts Produced by SLA
23.3.1.2 Digital Light Processing
23.3.1.2.1 Advantages and Disadvantages of DLP
23.3.1.2.2 Main Applications of Parts Produced by DLP
23.3.1.3 Continuous Digital Light Processing
23.3.2 Material Jetting
23.3.2.1 Continuous Stream or the Drop-on Demand Stream
23.3.2.2 Polyjet or Multijet Modeling
23.3.2.3 Nanoparticle Jetting
23.3.3 Material Extrusion
23.3.3.1 Fused Deposition Modeling
23.3.4 Powder Bed Fusion
23.3.4.1 Electron Beam Melting
23.3.4.2 Selective Laser Sintering
23.3.4.3 Selective Laser Melting
23.3.4.4 Selective Heat Sintering
23.3.4.5 Direct Metal Laser Sintering
23.3.5 Binder Jetting
23.3.5.1 3 DP Process (BJ-3DP)
23.3.5.2 Plaster-based 3D Printing Process (PB-3DP)
23.3.6 Directed Energy Deposition
23.3.6.1 Laser Metal Deposition
23.3.6.2 Laser-Engineered Net Shaping
23.3.7 Sheet Lamination
23.3.7.1 Laminated Object Manufacturing
23.3.7.2 Ultrasonic Consolidation
23.4 Fields of Application of AM
23.4.1 Aerospace Applications
23.4.2 Automotive Applications
23.4.3 Biomedical Applications
23.5 Challenges, Needs, and Recommendations of AM
23.5.1 Challenges and Needs
23.5.2 Recommendations
Review Questions
Problems
Bibliography
Chapter 24: Industry 4.0 Technologies
24.1 Industry 4.0
24.2 Industry 4.0 Technology Pillars
24.2.1 Big Data and AI Analytics
24.2.2 Horizontal and Vertical Integration
24.2.3 Cloud Computing
24.2.4 Benefits of Cloud Computing
24.2.4.1 Applications of Cloud Computing
24.2.5 Augmented Reality
24.2.5.1 Benefits of AR
24.2.5.2 AR Industrial Applications ( https://solutions.borderstates.com/)
24.2.6 Industrial Internet of Things (IIoT)
24.2.6.1 IIoT Assisting Technologies
24.2.6.2 Applications of IIoT
24.2.6.3 IIoT Advantages
24.2.7 Additive Manufacturing/3D Printing
24.2.8 Autonomous Robots
24.2.8.1 AMR Categories
24.2.8.2 AMR Benefits
24.2.8.3 AMR Applications
24.2.9 Simulation/Digital Twins
24.2.9.1 DT Levels
24.2.9.2 DT Benefits
24.2.9.3 DT Applications
24.2.10 Cybersecurity
24.3 Advantages of Industry 4.0
24.4 Benefits of Industry 4.0
24.5 Applications of Industry 4.0
24.6 Limitations of Industry 4.0
Review Questions
Bibliography
Chapter 25: Quality Control
25.1 Introduction
25.2 Statistical Quality Control
25.2.1 Statistical Principles
25.2.2 Statistical Process Control
25.2.3 Control Charts
25.2.4 Control Limits and Specifications
25.2.5 Process Capability
25.2.6 Acceptance Sampling and Control
25.3 Total Quality Control
25.4 The ISO 9000 Standard
25.5 Dimensional Control
25.5.1 Interchangeability
25.5.2 Tolerance
25.5.3 Fits
25.5.4 Geometric Dimensioning and Tolerancing
25.6 Measuring Quality Characteristics
25.7 Measuring Tools and Equipment
25.7.1 Limit Gauges
25.7.1.1 Plug Gauges
25.7.1.2 Snap Gauges
25.7.2 Dimensional Measurements
25.7.3 Angular Measurements
25.7.4 Geometrical Measurements
25.8 Coordinate-Measuring Machine
25.9 Surface Measurements
25.10 Nondestructive Testing and Inspection
25.11 Destructive Testing
Review Questions
Problems
Bibliography
Chapter 26: Automation in Manufacturing Technology
26.1 Introduction
26.2 Mechanization versus Automation
26.3 Automation and Production Quantity
26.4 Necessity for Introducing Automation
26.5 Manufacturing Systems
26.6 Flexible Manufacturing Systems
26.6.1 Elements of FMS
26.6.2 Features and Characteristics of FMS
26.6.3 New Developments in FMS Technology
26.7 Computer-Integrated Manufacturing
26.7.1 Computer-Aided Design
26.7.2 Computer-Aided Process Planning
26.7.3 Computer-Aided Manufacturing
26.8 Integrated Manufacturing Production System-Lean Production
26.8.1 Steps for Implementing IMPS (Lean Production)
26.8.2 JIT Production
26.9 Adaptive Control
26.10 Smart Manufacturing and Artificial Intelligence
26.10.1 Expert Systems
26.10.2 Machine Vision
26.10.3 Artificial Neural Networks
26.10.4 Natural Language Systems
26.10.5 Fuzzy Logic (Fuzzy Models)
26.11 Factory of Future
26.12 Concluding Remarks Related to Automated Manufacturing
Review Questions
Bibliography
Chapter 27: Health and Safety Aspects in Manufacturing
27.1 Introduction
27.2 Health and Safety at Work
27.3 Sources of Manufacturing Hazards
27.3.1 Hazards Due to Manual Handling
27.3.2 Hazards Due to Hand-Held Tools
27.3.3 Mechanical Machining
27.3.4 Electrical Hazards
27.3.5 Noise Hazards
27.3.6 Vibration Hazards
27.3.7 Chemical Hazards
27.3.8 Fire Hazards
27.3.9 Hazards Due to Workplace Stress
27.4 Personal Protective Equipment
27.5 Hazards of Manufacturing Operations
27.5.1 Melting of Metals
27.5.2 Sand Casting
27.5.3 Metal-Forming Operations
27.5.4 Machining Operations
27.5.4.1 Traditional Machining
27.5.4.2 Nontraditional Machining Processes
27.5.5 Welding
Review Questions
Bibliography
Index