Manufacturing Engineering and Technology SIXTH EDITION Serope Kalpakjian Illinois Institute of Technology Steven R. Schmid The University of Notre DamePreface xxi About the Authors xxiv Part General Introduction 1 11 What Is Manufacturing? 1 12 Product Design and Concurrent Engineering § 13 Design for Manufacture, Assembly, Disassembly, and Service 11 14 Green Design and Manufacturing 13 LS Selection of Materials 15 1.6 Selection of Manufacturing Processes 18 17 Computer-integrated Manufacturing 26 18 Quality Assurance and Total Quality Management 29 19 Lean Production and Agile Manufacturing 32 110 Manufacturing Costs and Global Competition 32 111 General Trends in Manufacturing 34 I: Fundamentals of Materials: Their Behavior and Manufacturing Properties 37 The Structure of Metals 40 1.1 Introduction 40 1.2 Types of Atomic Bonds 41 1.3 The Crystal Structure of Metals 42 14 Deformation and Strength of Single Crystals 44 1.5 Grains and Grain Boundaries 47 1.6 Plastic Deformation of Polycrystalline Metals $0 1.7 Recovery, Recrystallization, and Grain Growth 51 1.8 Cold, Warm, and Hot Working 52 Summary 53° Key Terms $3 Bibliography 54 Review Questions 54 — Qualitative Problems 54 Quantitative Problems 55 Synthesis, Design, and Projects $$ Mechanical Behavior, Testing, and Manufacturing Properties of Materials 56 2.1 Introduction 56 2.2 Tension 57 23° Compression 66Contents 24 Torsion 67 2.5 Bending (Flexure) 68 2.6 Hardness 68 27 Fatigue 74 28 Creep 75 2.9 Impact 75 2.10 Failure and Fracture of Materials in Manufacturing and in Service 76 211 Residual Stresses 81 2.12 Work, Heat, and Temperature 82 Summary 83 Key Terms 84 Bibliography 84 Review Questions 84 — Qualitative Problems 85 Quantitative Problems 85 Synthesis, Design, and Projects 86 Physical Properties of Materials 88 3.1 Introduction 88 3.2 Density 89 3.3 Melting Point 92 3.4 Specific Heat 92 3.5 Thermal Conductivity 93 3.6 Thermal Expansion 93 3.7 Electrical, Magnetic, and Optical Properties 94 3.8 Corrosion Resistance 95 Summary 97° Key Terms 97 Bibliography 98 Review Questions 98 Qualitative Problems 98 Quantitative Problems 98 Synthesis, Design, and Projects 99 Metal Alloys: Their Structure ancl Strengthening by Heat Treatment 100 4.1 Introduction 100 4.2 Structure of Alloys 101 43° Phase Diagrams 103 44 The Iron-Carbon System 107 49 The Iron-Iron-carbide Phase Diagram and the Development of Microstructures in Steels 108 4.6 Cast Irons 110 4.7 Heat Treatment of Ferrous Alloys 111 4.8 Hardenability of Ferrous Alloys 115 4.9 Heat Treatment of Nonferrous Alloys and Stainless Steels 117 4.10 Case Hardening 119 441 Annealing 121 4.12 Heat-treating Furnaces and Equipment 123 4.13. Design Considerations for Heat Treating 125