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1 INTRODUCTION AND OVERVIEW OF MANUFACTURING 1.1 What Is Manufacturing? 1.2 Materials in Manufacturing 1.3 Manufacturing Processes 1.4 Production Systems 1.5 Manufacturing Economics Part I Engineering Materials and Product Attributes 2 THE NATURE OF MATERIALS 2.1 Atomic Structure and the Elements 2.2 Bonding between Atoms and Molecules 2.3 Crystalline Structures 2.4 Noncrystalline (Amorphous) Structures 2.5 Engineering Materials 3 MECHANICAL PROPERTIES OF MATERIALS 3.1 Stress-Strain Relationships 3.2 Hardness 3.3 Effect of Temperature on Properties 3.4 Fluid Properties 3.5 Viscoelastic Behavior of Polymers 4 PHYSICAL PROPERTIES OF MATERIALS 4.1 Volumetric and Melting Properties 4.2 Thermal Properties 4.3 Mass Diffusion 4.4 Electrical Properties 4.5 Electrochemical Processes 5 ENGINEERING MATERIALS 5. 1 Metals and Their Alloys 5.2 Ceramics 5.3 Polymers 5.4 Composite Materials 6 DIMENSIONS, SURFACES, AND THEIR MEASUREMENT 6.1 Dimensions, Tolerances, and Related Attributes 6.2 Conventional Measuring Instruments and Gages 6.3 Surfaces 6.4 Measurement of Surfaces 6.5 Effect of Manufacturing Processes Part II Solidification Processes 7 FUNDAMENTALS OF METAL CASTING 7.1 Overview of Casting Technology 7.2 Heating and Pouring 7.3 Solidification and Cooling 8 METAL CASTING PROCESSES 8.1 Sand Casting 8.2 Other Expendable-Mold Casting Processes 8.3 Permanent-Mold Casting Processes 8.4 Foundry Practice 8.5 Casting Quality 8.6 Castability and Casting Economics 8.7 Product Design Considerations 9 GLASSWORKING 9.1 Raw Materials Preparation and Melting 9.2 Shaping Processes in Glassworking 9.3 Heat Treatment and Finishing 9.4 Product Design Considerations 10 SHAPING PROCESSES FOR PLASTICS 10.1 Properties of Polymer Melts 10.2 Extrusion 10.3 Production of Sheet and Film 10.4 Fiber and Filament Production (Spinning) 10.5 Coating Processes 10.6 Injection Molding 10.7 Compression and Transfer Molding 10.8 Blow Molding and Rotational Molding 10.9 Thermoforming 10.10 Casting 10.11 Polymer Foam Processing and Forming 10.12 Product Design Considerations 11 PROCESSING OF POLYMER MATRIX COMPOSITES AND RUBBER 11.1 Overview of PMC Processing 11.2 Open-Mold Processes 11.3 Closed-Mold Processes 11.4 Other PMC Shaping Processes 11.5 Rubber Processing and Shaping 11.6 Manufacture of Tires and Other Rubber Products Part III Particulate Processing of Metals and Ceramics 12 POWDER METALLURGY 12.1 Characterization of Engineering Powders 12.2 Production of Metallic Powders 12.3 Conventional Pressing and Sintering 12.4 Alternative Pressing and Sintering Techniques 12.5 Powder Metallurgy Materials and Economics 12.6 Product Design Considerations in Powder Metallurgy 13 PROCESSING OF CERAMICS AND CERMETS 13.1 Processing of Traditional Ceramics 13.2 Processing of New Ceramics 13.3 Processing of Cermets 13.4 Product Design Considerations Part IV Metal Forming and Sheet Metalworking 14 FUNDAMENTALS OF METAL FORMING 14.1 Overview of Metal Forming 14.2 Material Behavior in Metal Forming 14.3 Temperature in Metal Forming 14.4 Strain Rate Sensitivity 14.5 Friction and Lubrication in Metal Forming 14.6 Forming Limit Diagram 15 BULK DEFORMATION PROCESSES IN METAL WORKING 15.1 Rolling 15.2 Forging 15.3 Extrusion 15.4 Wire and Bar Drawing 16 SHEET METALWORKING 16.1 Cutting Operations 16.2 Bending Operations 16.3 Drawing 16.4 Equipment and Economics for Sheet-Metal Pressworking 16.5 Other Sheet-Metal-Forming Operations 16.6 Sheet-Metal Operations Not Performed on Presses 16.7 Bending of Tube Stock Part V Material Removal Processes 17 THEORY OF METAL MACHINING 17.1 Overview of Machining Technology 17.2 Theory of Chip Formation in Metal Machining 17.3 Force Relationships and the Merchant Equation 17.4 Power and Energy Relationships in Machining 17.5 Cutting Temperature 18 MACHINING OPERATIONS AND MACHINE TOOLS 18.1 Machining and Part Geometry 18.2 Turning and Related Operations 18.3 Drilling and Related Operations 18.4 Milling 18.5 Machining Centers and Turning Centers 18.6 Other Machining Operations 18.7 Machining Operations for Special Geometries 18.8 High-Speed Machining 19 CUTTING-TOOL TECHNOLOGY 19.1 Tool Life 19.2 Tool Materials 19.3 Tool Geometry 19.4 Cutting Fluids 20 ECONOMIC AND PRODUCT DESIGN CONSIDERATIONS IN MACHINING 20.1 Machinability 20.2 Tolerances and Surface Finish 20.3 Machining Economics 20.4 Product Design Considerations in Machining 21 GRINDING AND OTHER ABRASIVE PROCESSES 21.1 Grinding 21.2 Related Abrasive Processes 22 NONTRADITIONAL MACHINING AND THERMAL CUTTING PROCESSES 22.1 Mechanical Energy Processes 22.2 Electrochemical Machining Processes 22.3 Thermal Energy Processes 22.4 Chemical Machining 22. 5 Hybrid Machining Systems 22.6 Application Considerations Part VI Property Enhancing and Surface Processing Operations 23 HEAT TREATMENT OF METALS 23.1 Annealing 23.2 Martensite Formation in Steel 23.3 Precipitation Hardening 23.4 Surface Hardening 23.5 Heat Treatment Methods and Facilities 24 SURFACE PROCESSING OPERATIONS 24.1 Industrial Cleaning Processes 24.2 Diffusion and Ion Implantation 24.3 Plating and Related Processes 24.4 Conversion Coating 24.5 Vapor Deposition Processes 24.6 Organic Coatings 24.7 Porcelain Enameling and Other Ceramic Coatings 24.8 Thermal and Mechanical Coating Processes Part VII Joining and Assembly Processes 25 FUNDAMENTALS OF WELDING AND WELDING PROCESSES 25.1 Overview of Welding Technology 25.2 The Weld Joint 25.3 Physics of Welding 25.4 Features of a Fusion-Welded Joint 25.5 Arc Welding 25.6 Resistance Welding 25.7 Oxyfuel Gas Welding 25.8 Other Fusion-Welding Processes 25.9 Solid-State Welding 25.10 Weld Quality 25.11 Weldability and Welding Economics 25.12 Design Considerations in Welding 26 BRAZING, SOLDERING, AND ADHESIVE BONDING 26.1 Brazing 26.2 Soldering 26.3 Adhesive Bonding 27 MECHANICAL ASSEMBLY 27.1 Threaded Fasteners 27.2 Rivets and Eyelets 27.3 Assembly Methods Based on Interference Fits 27.4 Other Mechanical Fastening Methods 27.5 Molding Inserts and Integral Fasteners 27.6 Design for Assembly 27.7 DFMA Guidelines Part VIII Special Processing and Assembly Technologies (Available in e-text for students) 28 ADDITIVE MANUFACTURING 28.1 Fundamentals of Additive Manufacturing 28.2 Additive Manufacturing Technologies 28.3 Cycle Time and Cost Analysis 28.4 Additive Manufacturing Applications 28.5 File formats of Additive Manufacturing 29 PROCESSING OF INTEGRATED CIRCUITS 29.1 Overview of IC Processing 29.2 Silicon Processing 29.3 Lithography 29.4 Layer Processes Used in IC Fabrication 29.5 Integrating the Fabrication Steps 29.6 IC Packaging 29.7 Yields in IC Processing 30 ELECTRONICS ASSEMBLY AND PACKAGING 30.1 Electronics Packaging 30.2 Printed Circuit Boards 30.3 Printed Circuit Board Assembly 30.4 Electrical Connector Technology 31 MICROFABRICATION TECHNOLOGIES 31.1 Microsystem Products 31.2 Microfabrication Processes REFERENCES REVIEW QUESTIONS 32 NANOFABRICATION TECHNOLOGIES 32.1 Nanotechnology Products and Applications 32.2 Introduction to Nanoscience 32.3 Nanofabrication Processes Part IX Manufacturing Systems 33 AUTOMATION TECHNOLOGIES FOR MANUFACTURING SYSTEMS 33.1 Automation Fundamentals 33.2 Hardware for Automation 33.3 Computer Numerical Control 33.4 Industrial Robotics 34 INTEGRATED MANUFACTURING SYSTEMS 34.1 Material Handling 34.2 Fundamentals of Production Lines 34.3 Manual Assembly Lines 34.4 Automated Production Lines 34.5 Cellular Manufacturing 34.6 Flexible Manufacturing Systems 34.7 Computer-Integrated Manufacturing 34.7.1 Protocols used in Integrated Manufacturing Part X Manufacturing Support Systems 35 PROCESS PLANNING AND PRODUCTION CONTROL 35.1 Process Planning 35.2 Other Manufacturing Engineering Functions 35.3 Production Planning and Control 35.4 Just-in-Time Delivery Systems 35.5 Lean Production 35.6 Agile Production REFERENCES REVIEW QUESTIONS PROBLEMS 36 QUALITY CONTROL AND INSPECTION 36.1 Product Quality 36.2 Process Capability and Tolerances 36.3 Statistical Process Control 36.4 Quality Programs in Manufacturing 36.5 Inspection Principles 36.6 Modern Inspection Technologies REFERENCES STANDARD UNITS USED IN THIS BOOK ABBREVIATIONS USED IN THIS BOOK INDEX

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