Introduction to Manufacturing Processes and Materials

Front Cover
CRC Press, Mar 3, 1999 - Technology & Engineering - 416 pages
The first manufacturing book to examine time-based break-even analysis, this landmark reference/text applies cost analysis to a variety of industrial processes, employing a new, problem-based approach to manufacturing procedures, materials, and management. An Introduction to Manufacturing Processes and Materials integrates analysis of material costs and process costs, yielding a realistic, effective approach to planning and executing efficient manufacturing schemes. It discusses tool engineering, particularly in terms of cost for press work, forming dies, and casting patterns, process parameters such as gating and riser design for casting, feeds, and more.
 

Selected pages

Contents

The Role of Manufacturing in Global Economics Manufacturing Aids and Manufacturing BreakEven Analysis
3
12 Manufacturing Aids
5
13 Manufacturing BreakEven Analysis
9
14 The Internet and Manufacturing
18
17 Evaluative Questions
19
18 Research Questions
21
Internet Sources
22
Material and Design Considerations in Manufacturing
23
106 Estimating Costs for an InjectionMolded Part
205
107 Troubleshooting Part Defects
208
109 Evaluative Questions
209
References
210
Powder Processing
211
112 Powder Metallurgy Process
212
113 Process Advantages Unusual Properties and Process Limitations
215
114 Design Considerations
217

Basic Material Properties
25
23 Crystalline Structure
26
24 Miller Indices
31
25 Phase Diagrams
33
26 Summary
45
27 Evaluative Questions
46
References
48
Mechanical Material Property Relationships
49
33 True StressStrain
54
34 Relationships between Engineering StressStrain and True StressStrain
55
35 Strain Hardening Relationships and StressStrain Data
57
36 Hardness Relationships for Approximating Tensile Strength
58
37 Material Properties and Microstructure
59
38 Summary
63
References
65
Methods for Increasing Mechanical Material Properties
67
42 Solid Solution Hardening
68
44 Strengthening by Strain Hardening
69
45 Heat Treatment
75
46 Summary
82
47 Evaluative Questions
83
References
84
Material Codes and Coding Systems
85
53 Material Codes and Classification for Ferrous Materials
86
54 Coding for Aluminum Alloys
89
55 Material Codes and Properties
91
References
95
Design Material and Cost Relationships
97
63 MinimumCost Design for Strength Requirements for Simple Tension Loading
98
64 Design Performance Calculations for Other Types of Loading
103
65 Design Calculations with Multiple Constraints
105
66 Ashby Plots for Materials Evaluation
106
67 Summary
107
68 Evaluative Questions
108
69 Research Questions
109
References
114
Bibliography
115
Manufacturing Processes
117
Manufacturing Processes Overview
119
72 Casting Overview
123
73 Powder Processing Overview
125
74 Bulk Deformation Process Overview
126
75 Sheet Metal Process Overview
128
76 Machining Metal Removal or Cutting Overview
129
77 Joining Process Overview
131
78 Summary
132
References
133
Process Selection Basics
135
83 Summary
151
84 Evaluative Questions
152
References
154
Internet Sources
155
Metal Casting Process Considerations
157
92 Design Considerations in Casting
165
93 Casting Quality Considerations
166
94 Basic Theoretical Fundamentals for Casting
167
95 Fluidity Considerations
170
96 Basic Gating and Risering Design Calculations
171
97 Yield and Economic Considerations in Casting
184
98 Summary of the Casting Process
187
References
190
Bibliography
191
Plastic Parts Manufacturing
193
102 Classification of Polymers
194
104 Plastic Processes and Products from Various Polymers
201
115 Summary
221
References
223
Bulk Deformation Processing
225
122 Bulk Deformation Processes
227
123 Deformation Considerations
230
124 Force Determination
233
125 Forging Cost Estimating
240
126 Summary
241
127 Evaluative Questions
242
References
243
Internet Sources
244
Sheet Metal Forming
245
132 Defects in Sheet Metal Products
246
134 Shearing Types and Forces
250
135 Bending Stresses Minimum Bend Radius and Bend Length
253
136 Deep Drawing Calculations
257
137 Summary and Conclusions
262
References
264
Appendix 13A Alternative Shearing Force Formula
265
Machining Material Removal or Cutting Processes
267
142 Chip Formation
268
143 Machinability
270
145 Tool Wear Failure Mechanisms
271
146 Taylor ToolLife and Model
272
147 Classification of Machining Processes
274
148 Machining Variables and Relationships
277
149 GraphicalBased Approach to Feeds and Speeds
286
1410 Taylor ToolLife and Economics Model
288
1411 Detailed MetalCutting Problems
289
1412 Nonmechanical Nontraditional Machining
294
1413 Summary
295
References
297
Internet Sources
298
Derivation of Optimal ToolLife Values for MetalCutting Economics Models
299
Joining Processes Design and Economics
303
152 Fastener Categories and Descriptions
304
153 Adhesive Bonding
311
154 Cohesive Welding Joining Processes
315
155 Basic Welding Calculations
327
156 Welding Economics
330
157 Summary and Conclusions
335
References
339
Internet Sources
340
Manufacturing Support Functions
341
Tool Design for Manufacturing
343
162 Tool Design for Machining
344
163 Jigs and Fixtures
346
164 Dies for Manufacturing
352
165 Patterns for Sand Castings
354
166 Tools for Sheet Metal Work
355
167 Tools for Inspection and Gaging
360
168 Summary
365
169 Evaluative Questions
366
References
367
Failure Analysis and Prevention
369
172 Failure Types and Modes
372
173 Sources of Failure
374
174 Failure Analysis Procedure
376
175 Product Liability Issues
384
176 Summary
387
177 Evaluative Questions
388
Internet Sources
389
Index
391
Copyright

Other editions - View all

Introduction to Manufacturing Processes and Materials
Robert Creese
Limited preview - 2017
Introduction to Manufacturing Processes and Materials
Robert Creese
No preview available - 2019

Common terms and phrases

adhesive alloy aluminum amount angle anisotropic arc welding atom austenite basic bend blow molding bolt calculations carbide carbon cast iron casting process cavity cementite composition cooling cross-sectional area cutter cutting speed defects density determine diameter drill ductile electrode engineering strain EVALUATIVE QUESTIONS Example Problem extrusion failure feed ferrite Figure filler metal fixture forging fracture ft/min gages gating grain heat in./min indicated INTERNET SOURCES investment casting kpsi length load machining Manufacturing Processes martensite material cost material properties melting microconstituents modulus mold occur operations pearlite percent performance ratio phase diagram plastic polymers powder metallurgy primary product liability riser sand casting semivariable shape shear sheet metal shrinkage solidification sprue steel strain hardening strain ratio stress-strain structure Table Taylor tool-life tensile strength thickness tool true strain types unit cell values variable velocity volume weight welding processes workpiece yield strength

Bibliographic information

TitleIntroduction to Manufacturing Processes and Materials
Manufacturing Engineering and Materials Processing
AuthorRobert Creese
Editionillustrated
PublisherCRC Press, 1999
ISBN0824799143, 9780824799144
Length416 pages
Subjects › 

Business & Economics / Project Management
Technology & Engineering / Engineering (General)
Technology & Engineering / Manufacturing
Technology & Engineering / Materials Science
  
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