MANUFACTURING ENGINEERING AND TECHNOLOGY SIXTH EDITION IN SI UNITS Serope Kalpakjian Illinois Institute ofTechnology Steven R. Schmid The University ofNotre Dame SI Conversion by Hamldon Musa Universiti Teknologi Malaysia Prentice Hall Singapore London New York Toronto Sydney Tokyo Madrid Mexico City Munich Paris Capetown Hong Kong Montreal xiv lt gives us great pleasure to acknowledge the assistance of the following colleagues in the preparation and publication of this edition of the book: Komel F. Ehmann,Northwestern University;Klaus J.Weinmann, University of California at Berkeley; Timotius Pasang, AUT University; Miguel Sellés Canto, Escola Politecnica Superior d’Alcoi, Universitat Politécnica de Valencia, Spain; and Kevin Wilson,Michael Giordano and Megan McGann, University of Notre Dame.We also acknowledge Kent M. Kalpakjian as the originalauthor ofthe chapter on FabricationofMicroelectronic Devices. We would like to thank our editor, Holly Stark, at Prentice Hall for her enthusiastic support and guidance; and Clare Romeo, Production Editor, for her meticulous editorial and production supervision. We would also like to acknowledge the help of the following in the production of this edition of the book: Greg Dulles, A/V Project Manager; Daniel Sandin, Media Editor; William Opaluch, Editorial Assistant; and Kenny Beck,Cover Design. We are happy to present below a cumulative listof allthose individuals who generouslyhave made numerous contributions to various editions of our two books. B.J. Aaronson S. Chelikani D. Furrer R. Abella S. Chen R. Giese D.Adams S.-W. Choi E. Goode K.Anderson A. Cinar K.L. Graham S. Arellano R.O.Colantonio P. Grigg D.D. Arola P. Cotnoir M. Grujicic R.A.Arlt P.J. Courtney P.J. Guichelaar V.Aronov P. Demers B. Harriger A. Bagchi D. Descoteaux D. Harry E.D. Baker M.F. DeVries M. Hawkins J. Barak R.C. Dix R.J. Hocken J. Ben-Ari M. Dollar E.M. Honig,Jr. G.F.Benedict D.A. Domfeld Y. Huang S. Bhattacharyya H.I. Douglas S. Imam JT. Black M. Dugger R. Jaeger W. Blanchard D.R. Durham C. Johnson C. Blathras D. Duvall K. Jones G. Boothroyd S.A. Dynan D. Kalisz D. Bourell J. El Gomayel K.M. Kalpakjian B. Bozak M.G. Elliott J. Kamman N.N. Breyer N.X. Fang S.G. Kapoor C.A. Brown E.C. Feldy R. Kassing R.G. Bruce J. Field R.L.Kegg J Cesarone G.W. Fischer W.J.Kennedy T.-C. Chang D.A. Fowley R. Kerr R.L. Cheaney R.L. French T.Kesavadas A. Cheda B.R. Fruchter B.D.King J.E. Kopf C. Nair L. Soisson R.J. Koronkowski P.G. Nash P. Stewart Kotowski Nazemetz Stocker J J J S. Krishnamachari E.M. Odom L. Strom K.M. Kulkami N. Pacelli A.B. Strong T. Lach U. Pal K. Subramanian L. Langseth S. Paolucci T. Sweeney M. Laurent S.J. Parelukar W.G. Switalski M. Levine T. Pasang T. Taglialavore B.S. Levy Z.J. Pei M. Tarabishy J. Lewandowski J Penaluna K.S. Taraman X.Z. Li C. Petronis R. Taylor Z. Liang M. Philpott B.S. Thakkar B.W. Lilly M. Pradheeradhi A. Trager A. Lozier J.M.Prince A. Tseng D.A. Lucca D.W. Radford C. Tszang M. Madou W.J. Riffe M. Tuttle S. Mantell R.J. Rogalla S. Vaze L. Mapa Y. Rong J. Vigneau A. Marsan A.A. Runyan G.A. Volk R.J. Mattice P. Saha G. Wallace C. Maziar G.S. Saletta J.F. Wang T. McClelland M. Salimian K.J. Weinmann W. McClurg M. Savic R. Wertheim L. McGuire W.J. Schoech K.West K.E. McKee S.A. Schwartz J. Widmoyer K.P. Meade M. Selles K.R. Williams M.H. Miller S. Shepel G. Williamson R. Miller R. Shivpuri B. Wiltjer T.S. Milo M.T. Siniawski J. Wingfield D.J. Morrison J.E. Smallwood P.K. Wright S. Mostovoy J.P. Sobczak N. Zabaras We are also grateful to numerous organizations. companies, and individuals who supplied us with many ofthe illustrations and case studies. These contributions have been specificallyacknowledgedthroughoutthe text. It is withjoy that we gratefully dedicatethisbook to Professor JohnA. Schey, ouresteemed colleague anddistinguished researcher and author, whohas been a wise and great teacher, not only to generations of students but to his many colleagues as well. He and his wife, Gitta, have been treasured friends for many years. SEROPE KALPAKJIAN STEVEN R. SCHMID JANUARY 2009 xvi About the Author Serope Kalpakjian is a professor emeritus of mechanical and materials engineering at the Illinois Institute of Technology, Chicago. He is the author of Mechanical Processing ofMaterials (Van Nostrand, 1967) and co-author of Lubricants and Lubrication in Metalworking Operations (with E.S. Nachtman, Dekker, 1985). Both ofthe first editions ofhis booksManufacturing Processes for Engineering Materials (Addison-Wesley, 1984) and Manufacturing Engineering and Technology (Addison Wesley, 1989) have received the M. Eugene Merchant Manufacturing Textbook Award of SME. He has conducted research in several areas in manufacturingprocesses, is the author ofnumerous technical papersand articles in professional journals, handbooks, and encyclopedias, and hasedited several conferenceproceedings. He also has been editor and co-editor ofvarious technicaljournals and has served onthe editorial boardofEncyclopedia Americana. Professor Kalpakjian has received the Forging Industry Educational and Research Foundation Best Paper Award (1966); the Excellence in Teaching Award from the Illinois Institute of Technology(1970); the ASME Centennial Medallion (1980); the SME International Education Award (1989); a Person of the Millennium Award from IIT(1999); the Albert Easton White Outstanding Teacher Award from ASM International (2000); and the SME Outstanding Young Manufacturing Engineer Award for 2002 was named after him. Professor Kalpakjian is a Life Fellow of ASME; Fellow of SME; Fellow and Life Member of ASM International; Fellow Emeritus of The International Academy for Production Engineering (CIRP); and is a past president and founding member ofthe NorthAmerican Manufacturing Research Institution/ SME. He is a high-honors graduate of Robert College (Istanbul), Harvard University, and the Massachusetts Institute ofTechnology. XVII About the Author Steven R. Schmid is anAssociate Professor in the Department ofAerospace andMechanicalEngineeringat theUniversityofNotreDame,where heteaches and conducts research in the general areas ofmanufacturing, machine design, and tribology. He received his Bachelor’s degree in Mechanical Engineering from theIllinois Institute ofTechnology(with Honors) and Master’s and Ph.D. degrees, both in Mechanical Engineering, from Northwestern University. He hasreceivednumerous awards,includingtheJohnT.ParsonsAward fromSME (2000); the NewkirkAward from ASME (2000); the Kaneb Center Teaching Award (2000 and 2003); and the Ruth and Joel Spira Award for Excellence in Teaching (2005). He is also the recipient of a National Science Foundation CAREERSAward (1996) and anALCOA FoundationAward (1994). Professor Schmid is the author of almost l00 technical papers, has co- authored the texts Fundamentals of Machine Elements (McGraw-Hill), Fundamentals of Fluid Film Lubrication (Dekker), Manufacturing Processes for Engineering Materials (Prentice Hall), and has contributed two chapters to the CRCHandbook ofModern Tribology. He is anAssociate Editor ofthe ASMEJournal of Manufacturing Science and Engineering, and is a registered Professional Engineer and a CertifiedManufacturing Engineer of SME. About the Adaptor Hamidon Musa is Associate Professor with the Manufacturing Division in the Faculty of Mechanical Engineering at Universiti Teknologi Malaysia. He graduated from the University of Birmingham in 1980 and did his post- graduate studies at Cranfield Institute of Technology, UK. His main area of interest is non-traditional machining. Contents General Introduction 1 1.1 What 1s Manufacturing? 1 1.2 Product Design and ConcurrentEngineering 8 1.3 Design for Manufacture, Assembly, Disassembly, and Service 11 1.4 Green Design and Manufacturing 13 1.5 Selection of Materials 15 1.6 Selection of Manufacturing Processes 18 1.7 Computer-integrated Manufacturing 26 1.8 QualityAssurance and Total QualityManagement 29 1.9 Lean Production and Agile Manufacturing 32 1.10 Manufacturing Costs and Global Competition 32 1.11 GeneralTrends in Manufacturing 34 Part l: Fundamentals of Materials: Their Behavior and Manufacturing Properties 37 1 The Structure of Metals 40 1.1 Introduction 40 1.2 Types of Atomic Bonds 41 1.3 TheCrystal Structure of Metals 42 1.4 Deformation and Strength of Single Crystals 44 1.5 Grains and Grain Boundaries 47 1.6 Plastic Deformation of Polycrystalline Metals 50 1.7 Recovery, Recrystallization, and Grain Growth 51 1.8 Cold, Warm, and Hot Working 52 Summary 53 Key Terms 53 Bibliography 54 Review Questions 54 Qualitative Problems 54 Quantitative Problems 55 Synthesis, Design, and Projects 55 2 Mechanical Behavior, Testing, ancl Manufacturing Properties of Materials 56 2.1 Introduction 56 2.2 Tension 57 2.3 Compression 66 XIX 2.4 Torsion 67 2.5 Bending (Flexure) 68 2.6 Hardness 68 2.7 Fatigue 74 2.8 Creep 75 2.9 Impact 75 2.10 Failure and Fracture of Materials in Manufacturing and in Service 76 2.11 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 and Strengthening by Heat Treatment 100 4.1 Introduction 100 4.2 Structure of Alloys 101 4.3 Phase Diagrams 103 4.4 The Iron-Carbon System 107 4.5 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 4.11 Annealing 121 4.12 Heat-treating Furnaces and Equipment 123 4.13 Design Considerationsfor Heat Treating 125 XX Summary 126 Key Terms 127 Bibliography 127 Review Questions 127 Qualitative Problems 127 Quantitative Problems 128 Synthesis, Design, and Projects 128 Ferrous Metals and Alloys; Production, General Properties, and Applications 129 5.1 Introduction 129 5.2 Production of Iron and Steel 130 5.3 Casting of Ingots 133 5.4 Continuous Casting 134 5.5 Carbon and Alloy Steels 136 5.6 Stainless Steels 143 5.7 Tool and Die Steels 145 Summary 147 Key Terms 148 Bibliography 148 Review Questions 148 Qualitative Problems 149 Quantitative Problems 149 Synthesis, Design, and Projects 150 Nonferrous Metals and Alloys: Production, General Properties, and Applications 151 6.1 Introduction 151 6.2 Aluminum and Aluminum Alloys 152 6.3 Magnesium and Magnesium Alloys 157 6.4 Copper and Copper Alloys 158 6.5 Nickel and Nickel Alloys 160 6.6 Superalloys 161 6.7 Titaniumand Titanium Alloys 162 6.8 Refractory Metals and Alloys 163 6.9 Beryllium 164 6.10 Zirconium 164 6.11 Low-melting Alloys 164 6.12 Precious Metals 166 6.13 Shape-memory Alloys (SmartMaterials) 166 6.14 Amorphous Alloys (Metallic Glasses) 167 6.15 Metal Foams 167 Summary 168 Key Terms 168 Bibliography 169 Review Questions 169 Qualitative Problems 169 Quantitative Problems 170 Synthesis, Design, and Projects 170 Polymers: Structure, General Properties, and Applications 171 7.1 Introduction 171 7.2 TheStructure of Polymers 173 7.3 Thermoplastics 180 7.4 Thermosetting Plastics 184 XXI 7.5 Additivesin Plastics 184 7.6 General Properties and Applications of Thermoplastics 185 7.7 General Properties and Applications of Thermosetting Plastics 188 7.8 Biodegradable Plastics 190 7.9 Elastomers (Rubbers) 191 Summary 192 Key Terms 193 Bibliography 193 Review Questions 194 Qualitative Problems 194 Quantitative Problems 195 Synthesis, Design, and Projects 195 8 Ceramics, Graphite, Diamond, and Nanomaterials: Structure, General Properties, and Applications 196 8.1 Introduction 196 8.2 TheStructure of Ceramics 197 8.3 GeneralProperties and Applications of Ceramics 201 8.4 Glasses 205 8.5 Glass Ceramics 207 8.6 Graphite 208 8.7 Diamond 210 8.8 Nanomaterials 210 Summary 212 Key Terms 212 Bibliography 213 Review Questions 213 Qualitative Problems 214 Quantitative Problems 214 Synthesis, Design, and Projects 214 9 Composite Materials: Structure, General Properties, and Applications 216 9.1 Introduction 216 9.2 The Structure of Reinforced Plastics 217 9.3 Properties of Reinforced Plastics 222 9.4 Applications of Reinforced Plastics 225 9.5 Metal-matrix Composites 227 9.6 Ceramic-matrix Composites 229 9.7 Other Composites 230 Summary 231 Key Terms 231 Bibliography 231 Review Questions 232 Qualitative Problems 232 Quantitative Problems 233 Synthesis, Design, and Projects 233 Part II: Metal-Casting Processes ancl Equipment 235 l 0 Fundamentals of Metal Casting 237 10.1 Introduction 237 10.2 Solidification of Metals 238 xxii