Fundamentals of Modern Manufacturing: Materials, Processes, and Systems

1124 Pages·2012·18.13 MB·English

by  Mikell P. Groover

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FEATURES OF THIS BOOK AND ITS WEBSITE
FOR STUDENTS:
Fundamentals of Modern Manufacturing: Materials, Processes, and Systems con-
tains 40 chapters. Chapter 1 provides an introduction and overview of manufactur-
ing. Chapters 2 through 9 are concerned with engineering materials and product
attributes; Chapters 10 through 36 cover manufacturing processes and related tech-
nologies; and Chapters 37 through 40 describe the systems of manufacturing.
To assist in the learning process for students, the following materials are provided
in the book:
➢ More than 550 end-of-chapter Problems. The answers to selected problems can
be found in an Appendix at the back of the book (before the Index).
➢ Many numerical example problems throughout the text. These example problems
are similar to some of the end-of-chapter exercise problems.
➢ More than 750 end-of-chapter Review Questions. These questions are descriptive
whereas nearly all of the end-of-chapter Problems are quantitative.
➢ Historical Notes describing the origins of many of the manufacturing topics
discussed in the book.
➢ Units used in the book (International System and U.S. Customary System) are
provided in the inside back cover, which also includes procedures for converting
between SI and USCS units.
In addition, we have provided the following materials on the companion website for
the book:
➢ Video clips of many of the manufacturing processes and related topics that are
described in the book.
➢ More than 600 Multiple Choice Quiz questions, one quiz for each chapter,
which can be used by students to test their knowledge of chapter topics. Stu-
dents should consult with their instructors about the availability of the correct
answers to these questions.
To access the website, go to www.wiley.com/college/groover. After entering the web-
site, students should select the link for this book and click on “student companion site”
to access the content for students.
FOR INSTRUCTORS:
For instructors who adopt the book for their courses, the following support materials
are available on the companion website for the book:
➢ A set of Powerpoint slides for all chapters for instructors to use in their class
lectures. Instructors can decide whether to make these slides available to their
students.
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➢ A series of video clips of many of the processes discussed in the book. These
video clips can be used in class to illustrate the processes, and students can also
view these clips independently on the website.
➢ A Solutions Manual covering all review questions and end-of-chapter problems
in the book. Instructors can use these materials as homework exercises and/or
to design tests and exams for their courses.
➢ A set of multiple choice quizzes, one quiz for each chapter, with a separate folder
for instructors that includes answers to the quiz questions. Instructors can decide
whether to make the answers available to their students. Instructors can also use
the quiz questions to design tests and exams for their courses.
➢ A set of case studies developed by Prof. Dan Waldorf of California Polytechnic
University at San Luis Obispo. These case studies are designed to be used in
conjunction with the video clips located on the website as well as the book.
Instructors can use these materials as homework or laboratory exercises.
To access the website, go to www.wiley.com/college/groover. After entering the
website, instructors should select the link for this book and click on “instructor
companion site” to access the content for instructors.
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Fundamentals
of Modern
Manufacturing
Materials, Processes, and Systems
Fifth Edition
Mikell P. Groover
Professor Emeritus of Industrial and
Systems Engineering Lehigh University
The author and publisher gratefully acknowledge the contributions
of Dr. Gregory L. Tonkay, Associate Professor of Industrial and Systems
Engineering, and Associate Dean, College of Engineering and
Applied Science, Lehigh University.
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VICE PRESIDENT AND EXECUTIVE PUBLISHER Don Fowley
ACQUISITION EDITOR Linda Ratts
SENIOR CONTENT MANAGER Lucille Buonocore
SENIOR PRODUCTION EDITOR Anna Melhorn
SENIOR DESIGNER Jim O’Shea
EDITORIAL ASSISTANT Christopher Teja
MARKETING MANAGER Christopher Ruel
CREATIVE DIRECTOR Harry Nolan
PRODUCTION SERVICES Suzanne Ingrao/Ingrao Associates
FRONT COVER PHOTO Courtesy of Kennametal, Inc.
This book was set in Times Roman by Thomson Digital, and printed and bound by Quad Graphics/Versailles.
This book is printed on acid-free paper. ∞
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978-1-118-231463
Printed in the United States of America
10 9 8 7 6 5 4 3 2 1
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PREFACE
Fundamentals of Modern Manufacturing: Materials, Processes, and Systems is
designed for a fi rst course or two-course sequence in manufacturing at the junior
level in mechanical, industrial, and manufacturing engineering curricula. Given
its coverage of engineering materials, it may also be suitable for materials science
and engineering courses that emphasize materials processing. Finally, it may be
appropriate for technology programs related to the preceding engineering dis-
ciplines. Most of the book’s content is concerned with manufacturing processes
(about 65% of the text), but it also provides signifi cant coverage of engineering
materials and production systems. Materials, processes, and systems are the basic
building blocks of modern manufacturing and the three broad subject areas cov-
ered in the book.
APPROACH
The author’s objective in this and the preceding editions is to provide a treatment of
manufacturing that is modern and quantitative. Its claim to be “modern” is based on
(1) its balanced coverage of the basic engineering materials (metals, ceramics, poly-
mers, and composite materials), (2) its inclusion of recently developed manufactur-
ing processes in addition to the traditional processes that have been used and refi ned
over many years, and (3) its comprehensive coverage of electronics manufacturing
technologies. Competing textbooks tend to emphasize metals and their processing at
the expense of the other engineering materials, whose applications and methods of
processing have grown signifi cantly in the last several decades. Also, most competing
books provide minimum coverage of electronics manufacturing. Yet the commercial
importance of electronics products and their associated industries have increased
substantially during recent decades.
The book’s claim to be more “quantitative” is based on its emphasis on manu-
facturing science and its greater use of mathematical models and quantitative
(end-of-chapter) problems than other manufacturing textbooks. In the case of
some processes, it was the fi rst book on manufacturing processes to provide a
quantitative engineering coverage of the topic.
ORGANIZATION OF THE BOOK
The fi rst chapter provides an introduction and overview of manufacturing. Manu-
facturing is defi ned, and the materials, processes, and systems of manufacturing are
briefl y described. New to this edition is a section on manufacturing economics. The
chapter concludes with a list of developments that have affected manufacturing over
the past 50 or so years.
The remaining 39 chapters are organized into 11 parts. Part I, titled Material
Properties and Product Attributes, consists of four chapters that describe the impor-
tant characteristics of materials and the products made from them. Part II discusses
the four basic engineering materials: metals, ceramics, polymers, and composites.
iii
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iv Preface
Part III begins the coverage of the part-shaping processes, which are organized
into four categories: (1) solidifi cation processes, (2) particulate processes, (3) defor-
mation processes, and (4) material removal processes. Part III consists of six chap-
ters on the solidifi cation processes that include casting of metals, glassworking, and
polymer shaping. In Part IV, the processing of powders of metals and ceramics is
covered in two chapters. Part V deals with metal deformation processes such as roll-
ing, forging, extrusion, and sheet metalworking. Finally, Part VI discusses the material
removal processes. Four chapters are devoted to machining, and two chapters cover
grinding (and related abrasive processes) and the nontraditional material removal
technologies.
Part VII consists of two chapters on other types of processing operations: property
enhancing processes and surface processing. Property enhancing is accomplished by
heat treatment, and surface processing includes operations such as cleaning, electro-
plating, vapor deposition processes, and coating (painting).
Joining and assembly processes are considered in Part VIII, which is organized
into four chapters on welding, brazing, soldering, adhesive bonding, and mechanical
assembly.
Several unique processes that do not neatly fi t into the preceding classifi cation
scheme are covered in Part IX, titled Special Processing and Assembly Technologies.
Its fi ve chapters cover rapid prototyping and additive manufacturing, processing of
integrated circuits, electronics assembly, microfabrication, and nano fabrication.
Part X begins the coverage of the systems of manufacturing. Its two chapters
deal with the types of automation technologies in a factory, such as numerical
control and industrial robotics, and how these technologies are integrated into
systems, such as production lines, manufacturing cells, and fl exible manufactur-
ing systems. Finally, Part XI deals with manufacturing support systems: process
planning, production planning and control, lean production, and quality control
and inspection.
NEW TO THIS EDITION
This fi fth edition builds on the fourth edition. The content has been increased and
this is refl ected in the page count. In previous editions, the author has attempted to
keep the page count at around 1000. The fi fth edition contains about 1100 pages.
Additions and changes in the fi fth edition include the following:
➢ The chapter count has been reduced from 42 to 40 through consolidation of
several chapters. The two chapters in the fourth edition on rubber processing
(Chapter 14) and polymer matrix composites processing (Chapter 15) have
been combined into a single chapter, and the two chapters in the fourth edi-
tion on process planning (Chapter 40) and production planning and control
(Chapter 41) have been combined into one chapter.
➢ In Chapter 1, two new sections have been added on manufacturing econom-
ics (cycle time and cost analysis) and recent developments that have affected
manufacturing.
➢ Troubleshooting guides have been added to several of the machining chapters.
➢ The chapter on rapid prototyping has been extensively revised, and a new sec-
tion on cycle time and cost analysis has been added. The chapter title has been
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Preface v
changed to Rapid Prototyping and Additive Manufacturing to refl ect the evolu-
tion of the RP technologies.
➢ The chapter on integrated circuit processing has been updated. The coverage of
Rent’s rule has been expanded to include how the rule can be applied to several
different types of integrated circuits.
➢ The chapter on electronics packaging has been reorganized, with more empha-
sis on surface mount technology.
➢ A new section on the classifi cation of nanotechnology products has been added
to the chapter on nanofabrication.
➢ A section on mass customization has been added in the chapter on integrated
manufacturing systems.
➢ A section on lean production and the Toyota production system has been added
to the chapter on process planning and production control.
➢ New historical notes have been added on metrology, rapid prototyping, and lean
production.
➢ The number of example problems imbedded in the text has been increased from
47 in the fourth edition to 65 in the fi fth. Included are new example problems
on manufacturing economics, tensile testing, machining time, rapid prototyping
costs, and integrated circuit processing.
➢ More than 60% of the end-of-chapter problems are new or revised, and the
total number of end-of-chapter problems has been increased. End-of-chapter
problems have been labeled as using either SI or USCS units, so if instructors
want to assign problems with only one type of units, this will help them identify
the problems that are of the desired type. Answers to selected end-of-chapter
problems are provided in an appendix at the back of the book.
➢ The multiple choice quizzes that were included at the end of each chapter in the
fourth edition are now available on the website for the book. The total number
of multiple choice questions has been increased from 495 in the fourth edition
to 745 for the fi fth edition.
➢ The DVD that was included with the fourth edition has now been made avail-
able as a collection of video clips on the website for the book.
SUPPORT MATERIAL FOR INSTRUCTORS
For instructors who adopt the book for their courses, the following support materials
are available on the website for the book:
➢ A complete set of Powerpoint slides for all chapters is available to instructors
for their class lectures. Instructors can decide whether to make these slides
available to their students.
➢ A series of video clips of many of the processes discussed in the book are avail-
able on the website for the book. These can be used in class to illustrate the
processes, and students can also view these clips independently on the website.
➢ A Solutions Manual (in digital format) covering all review questions and end-
of-chapter problems is available on the website for the book. Instructors can use
these materials as homework exercises or to make up quizzes for their courses.
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vi Preface
➢ An extensive set of multiple choice quizzes (with a separate folder that includes
answers to the quiz questions) is available for instructors to provide to their
students as individual learning exercises or to make up quizzes for their courses.
➢ A set of case studies developed by Prof. Dan Waldorf of California Polytechnic
University is available on the website for the book. These case studies are designed
to be used in conjunction with the video clips located on the website. Instructors
can use these materials as homework or laboratory exercises.
These support materials may be found at the website www.wiley.com/college/groover.
Evidence that the book has been adopted as the main textbook for the course must be
verifi ed. Individual questions or comments may be directed to the author personally
at [email protected].
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