Manufacturing Processes for Engineering Materials, 4/E

Serope Kalpakjian, Illinois Institute of Technology

Steven R. Schmid, The University of Notre Dame
ISBN: 0-13-040871-9, Publisher: Prentice Hall (Copyright: 2003). Cloth; 976 pp
Published: 08/14/2002

Table of Contents
(NOTE: Each chapter begins with an Introduction.)
General Introduction.
What Is Manufacturing? Examples of Manufactured Products. The Design Process and Concurrent Engineering.
Design for Manufacture, Assembly, Disassembly, and Service. Selecting Materials. Selecting Manufacturing
Processes. Computer-Integrated Manufacturing. Quality Assurance and Total Quality Management. Global
Competitiveness and Manufacturing Costs. Lean Production and Agile Manufacturing. Environmentally-
Conscious Design and Manufacturing. Product Liability. Organization for Manufacture.

I. FUNDAMENTALS OF MATERIALS: THEIR BEHAVIOR AND MANUFACTURING PROPERTIES.

1. The Structure of Metals.

The Crystal Structure of Metals. Deformation and Strength of Single Crystals. Grains and Grain Boundaries.
Plastic Deformation of Polycrystalline Metals. Recovery, Recrystallization, and Grain Growth. Cold-, Warm-, and
Hot-Working.

2. Mechanical Behavior, Testing, and Manufacturing Properties of Materials.

Tension. Compression. Tension. Bending (Flexure). Hardness. Fatigue. Creep. Impact. Failure and Fracture of
Materials in Manufacturing and Service. Residual Stresses. Work, Heat, and Temperature.

3. Physical Properties of Materials.

Density. Melting Point. Specific Heat. Thermal Conductivity. Thermal Expansion. Electrical, Magnetic, and
Optical Properties. Corrosion Resistance.

4. Metal Alloys: Their Structure and Strengthening by Heat Treatment.

Structure of Alloys. Phase Diagrams. The Iron-Carbon System. The Iron-Iron Carbide Phase Diagram and the
Development of Microstructures in Steels. Cast Irons. Heat Treatment of Ferrous Alloys. Hardenability of Ferrous
Alloys. Heat Treatment of Nonferrous Alloys and of Stainless Steels. Case Hardening. Annealing. Heat-Treating
Furnaces and Equipment. Design Considerations for Heat Treating.

5. Ferrous Metals and Alloys: Production, General Properties and Applications.

Production of Iron and Steel. Casting of Ingots. Continuous Casting. Carbon and Alloy Steels. Stainless Steels.
Tool and Die Steels.

6. Nonferrous Metals and Alloys: Production, General Properties, and Applications.

Aluminum and Aluminum Alloys. Magnesium and Magnesium Alloys. Copper and Copper Alloys. Nickel and
Nickel Alloys. Superalloys. Titanium and Titanium Alloys. Refractory Metals and Alloys. Beryllium. Zirconium.
Low-Melting Alloys. Precious Metals. Shape-Memory Alloys. Amorphous Alloys. Nanomaterials.

7. Polymers: Structure, General Properties, and Applications.

The Structure of Polymers. Thermoplastics. Thermosetting Plastics. Additives in Plastics. General Properties and
Applications of Thermoplastics. General Properties and Applications of Thermosetting Plastics. Biodegradable
Plastics. Elastomers (Rubbers).

8. Ceramics, Graphite, and Diamond: Structure, General Properties, and Applications.

The Structure of Ceramics. General Properties and Applications of Ceramics. Glasses. Glass Ceramics. Graphite.
Diamond.

9. Composite Materials: Structure, General Properties, and Applications.

 The Structure of Reinforced Plastics. Properties of Reinforced Plastics. Applications of Reinforced Plastics. Metal-
Matrix Composites. Ceramic-Matrix Composites. Other Composites.

II. METAL-CASTING PROCESSES AND EQUIPMENT.

10. Fundamentals of Metal Casting.

Solidification of Metals. Fluid Flow. Fluidity of Molten Metal. Heat Transfer. Defects.

11. Metal-Casting Processes.

Sand Casting. Shell-Mold Casting. Expendable-Pattern Casting (Lost Foam). Plaster-Mold Casting. Ceramic-Mold
Casting. Investment Casting. Vacuum Casting. Permanent-Mold Casting. Slush Casting. Pressure Casting. Die
Casting. Centrifugal Casting. Squeeze Casting and Semisolid-Metal Forming. Casting Techniques for Single-
Crystal Components. Rapid Solidification (Amorphous Alloys). Inspection of Castings. Melting Practice and
Furnaces. Foundries and Foundry Automation.

12. Metal Casting: Design, Materials, and Economics.

Design Considerations. Casting Alloys. The Economics of Casting.

III. FORMING AND SHAPING PROCESSES AND EQUIPMENT.

13. Rolling of Metals.

Flat Rolling. Flat-Rolling Practice. Rolling Mills. Shape-Rolling Operations. Production of Seamless Tubing and
Pipe. Continuous Casting and Rolling; Integrated Mills and Minimills.

14. Forging of Metals.

Open-Die Forging. Impression-Die and Closed-Die Forging. Related Forging Operations. Rotary Swaging.
Forging Die-Design. Die Materials and Lubrication. Forgeability. Forging Machines. Forging Practice and Process
Capabilities. Die Manufacturing Methods. Die Failures. The Economics of Forging.

15. Extrusion and Drawing of Metals.

The Extrusion Process. Extrusion Practice. Hot Extrusion. Cold Extrusion. Impact Extrusion. Hydrostatic
Extrusion. Extrusion Defects. Extrusion Equipment. The Drawing Process. Drawing Practice. Defects and
Residual Stresses. Drawing Equipment.

16. Sheet-Metal Forming Processes.

Shearing. Sheet-Metal Characteristics. Test Methods for Formability of Sheet Metals. Bending Sheet and Plate.
Common Bending Operations. Tube Bending and Forming. Stretch Forming. Deep Drawing. Rubber Forming.
Spinning. Superplastic Forming. Explosive, Magnetic-Pulse, Peen, and Other Forming Processes. The
Manufacturing of Honeycomb Structures. The Dent Resistance of Sheet-Metal Parts. Equipment for Sheet-Metal
Forming. The Economics of Sheet-Metal Forming Processes.

17. Processing of Powder Metals, Ceramics, Glass, and Superconductors.

Production of Metal Powders. Compaction of Metal Powders. Sintering. Secondary and Finishing Operations.
Design Considerations for Powder Metallurgy. Process Capabilities. Economics of Powder Metallurgy. Shaping
Ceramics. Forming and Shaping of Glass. Techniques for Strengthening and Treating Glass. Design
Considerations for Ceramics and Glasses. Processing of Superconductors.

18. Forming and Shapi ng Plastics and Composite Materials.

Extrusion. Injection Molding. Blow Molding. Rotational Molding. Thermoforming. Compression Molding.
Transfer Molding. Casting. Cold Forming and Solid-Phase Forming. Processing Elastomers. Processing
Reinforced Plastics. Processing Metal-Matrix Composites. Processing Ceramic-Matrix Composites. Design
Considerations and Economics of Forming and Shaping Plastics.

19. Rapid Prototyping Operations.

Subtractive Processes. Additive Processes. Virtual Prototyping. Applications.
IV. MATERIAL-REMOVAL PROCESSES AND MACHINES.

20. Fundamentals of Cutting.

The Mechanics of Chip Formation. The Types of Chips Produced in Metal-Cutting. The Mechanics of Oblique
Cutting. Cutting Forces and Power. Temperatures in Cutting. Tool Life: Wear and Failure. Surface Finish and
Integrity. Machinability.

21. Cutting-Tool Materials and Cutting Fluids.

Carbon and Medium-Alloy Steels. High-Speed Steels. Cast-Cobalt Alloys. Carbides. Coated Tools. Alumina-
Based Ceramics. Cubic Boron Nitride. Silicon-Nitride Based Ceramics. Diamond. Whisker-Reinforced Tool
Materials. Cutting-Tool Reconditioning. Cutting Fluids.

22. Machining Processes Used to Produce Round Shapes.

Turning Parameters. Lathes and Lathe Operations. High-Speed Machining, Ultraprecision Machining, and Hard
Tuning. Cutting Screw Threads. Boring and Boring Machines. Drilling and Drills. Drilling Machines. Reaming
and Reamers. Tapping and Taps. Design Considerations for Drilling, Reaming and Tapping.

23. Machining Processes Used to Produce Various Shapes.

Milling Operations. Milling Ma