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Ch01 PDF
Ch01 PDF
Kalpakjian Schmid
Manufacturing Engineering and Technology
2001 Prentice-Hall
Page 1-1
Chapter 1 Outline
Kalpakjian Schmid
Manufacturing Engineering and Technology
2001 Prentice-Hall
Page 1-2
Figure 1.2 The body-centered cubic (bcc) crystal structure: (a) hard-ball model; (b) unit cell; and (c) single
crystal with many unit cells. Source: W. G. Moffatt, et al., The Structure and Properties of Materials, Vol. 1,
John Wiley & Sons, 1976.
Kalpakjian Schmid
Manufacturing Engineering and Technology
2001 Prentice-Hall
Page 1-3
Figure 1.3 The face-centered cubic (fcc) crystal structure: (a) hard-ball model; (b) unit cell; and (c) single
crystal with many unit cells. Source: W. G. Moffatt, et al., The Structure and Properties of Materials, Vol. 1,
John Wiley & Sons, 1976.
Kalpakjian Schmid
Manufacturing Engineering and Technology
2001 Prentice-Hall
Page 1-4
Kalpakjian Schmid
Manufacturing Engineering and Technology
2001 Prentice-Hall
Page 1-5
2001 Prentice-Hall
Page 1-6
Kalpakjian Schmid
Manufacturing Engineering and Technology
2001 Prentice-Hall
Page 1-7
Kalpakjian Schmid
Manufacturing Engineering and Technology
2001 Prentice-Hall
Page 1-8
Figure 1.9 Schematic illustration of types of defects in a single-crystal lattice: selfinterstitial, vacancy, interstitial, and substitutional.
Kalpakjian Schmid
Manufacturing Engineering and Technology
2001 Prentice-Hall
Page 1-9
Figure 1.10 Movement of an edge dislocation across the crystal lattice under a shear stress.
Dislocations help explain why the actual strength of metals in much lower than that predicted by
theory.
Kalpakjian Schmid
Manufacturing Engineering and Technology
2001 Prentice-Hall
Page 1-10
Solidification
Figure 1.11 Schematic
illustration of the stages
during solidification of
molten metal; each small
square represents a unit cell.
(a) Nucleation of crystals at
random sites in the molten
metal; note that the
crystallographic orientation
of each site is different. (b)
and (c) Growth of crystals as
solidification continues. (d)
Solidified metal, showing
individual grains and grain
boundaries; note the different
angles at which neighboring
grains meet each other.
Source: W. Rosenhain.
Kalpakjian Schmid
Manufacturing Engineering and Technology
2001 Prentice-Hall
Page 1-11
Grain Sizes
TABLE 1.1
ASTM No.
3
2
1
0
1
2
3
4
5
6
7
8
9
10
11
12
Kalpakjian Schmid
Manufacturing Engineering and Technology
Grains/mm2
1
2
4
8
16
32
64
128
256
512
1,024
2,048
4,096
8,200
16,400
32,800
Grains/mm3
0.7
2
5.6
16
45
128
360
1,020
2,900
8,200
23,000
65,000
185,000
520,000
1,500,000
4,200,000
2001 Prentice-Hall
Page 1-12
Preferred Orientation
Figure 1.12 Plastic deformation of
idealized (equiaxed) grains in a
specimen subjected to compression
(such as occurs in the rolling or forging
of metals): (a) before deformation; and
(b) after deformation. Note hte
alignment of grain boundaries along a
horizontal direction; this effect is
known as preferred orientation.
Kalpakjian Schmid
Manufacturing Engineering and Technology
2001 Prentice-Hall
Page 1-13
Anisotropy
(b)
Figure 1.13 (a) Schematic illustration of a crack in sheet metal that has been subjected to bulging
(caused by, for example, pushing a steel ball against the sheet). Note the orientation of the crack with
respect to the rolling direction of the sheet; this sheet is anisotropic. (b) Aluminum sheet with a crack
(vertical dark line at the center) developed in a bulge test; the rolling direction of the sheet was vertical.
Source: J.S. Kallend, Illinois Institute of Technology.
Kalpakjian Schmid
Manufacturing Engineering and Technology
2001 Prentice-Hall
Page 1-14
Annealing
Figure 1.14 Schematic illustration of the
effects of recovery, recrystallization, and
grain growth on mechanical properties
and on the shape and size of grains. Note
the formation of small new grains during
recrystallization. Source: G. Sachs.
Kalpakjian Schmid
Manufacturing Engineering and Technology
2001 Prentice-Hall
Page 1-15
TABLE 1.2
Process
Cold working
Warm working
Hot working
Kalpakjian Schmid
Manufacturing Engineering and Technology
T/Tm
< 0.3
0.3 to 0.5
> 0.6
2001 Prentice-Hall
Page 1-16