Manufacturing Technology: Materials, Processes, and Equipment, 1st Edition (Paperback) book cover

Manufacturing Technology

Materials, Processes, and Equipment, 1st Edition

By Helmi A. Youssef, Hassan A. El-Hofy, Mahmoud H. Ahmed

CRC Press

948 pages | 861 B/W Illus.

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Individuals who will be involved in design and manufacturing of finished products need to understand the grand spectrum of manufacturing technology. Comprehensive and fundamental, Manufacturing Technology: Materials, Processes, and Equipment introduces and elaborates on the field of manufacturing technology—its processes, materials, tooling, and equipment. The book emphasizes the fundamentals of processes, their capabilities, typical applications, advantages, and limitations. Thorough and insightful, it provides mathematical modeling and equations as needed to enhance the basic understanding of the material at hand.

Designed for upper-level undergraduates in mechanical, industrial, manufacturing, and materials engineering disciplines, this book covers complete manufacturing technology courses taught in engineering colleges and institutions worldwide. The book also addresses the needs of production and manufacturing engineers and technologists participating in related industries.


"…describes the fundamentals of processes, their capabilities, typical applications, advantages and limitations. … a useful reference for students at technical colleges, mechanical, manufacturing, industrial and materials engineers, professionals in related industries with manufacturing technology."

—Int. J. Machining and Machinability of Materials, Vol. 13, No. 4, 2013

Table of Contents

Importance of Manufacturing Technology

Selection of Materials and Manufacturing Processes

Company Organization

Role of Computers in Modern Manufacturing Technology

Planning for Manufacturing

Accuracy of Manufacturing Processes

Economical and Environmental Considerations

Health and Safety Aspects

Properties of Engineering Materials


Physical Properties

Mechanical Properties

Manufacturing (Fabricating) Properties

Structure of Metals and Alloys


Lattice Structure of Metals

Imperfections in Lattice Structure

Solidification of Metals and Alloys

Engineering Materials and Their Applications


Classification of Engineering Materials

Ferrous Metals and Alloys

Nonferrous Metals and Alloys

Newly Born Engineering Materials

Heat Treatment of Metals and Alloys


Heat Treatment of Steels

Basic Heat Treatment Operations of Steels

Heat Treatment of Cast Iron

Heat Treatment of Nonferrous Alloys and Stainless Steels

(Precipitation Hardening)

Smelting of Metallic Materials


Smelting of Ferrous Metals

Smelting and Extraction of Nonferrous Metals

Casting of Metallic Materials

Introduction and Classification

Historical Development of Casting

Expendable Mold Casting Processes

Permanent Mold Castings

Melting Furnaces

Cleaning and Finishing of Castings

Quality of Castings

Modeling of Casting

Fundamentals of Metal Forming


Simple Stresses and Strains

Two- and Three-Dimensional Stresses and Strains

Yield Criteria

General Plastic Stress–Strain Relations (Theory of Plasticity)

Effect of Temperature on Plastic Deformation

Cold, Warm, and Hot Forming

Effect of Strain Rate on Plastic Deformation


Effect of Friction and Lubrication in Metal Forming

Bulk Forming of Metallic Materials


Classification of Forming Processes

Forging Processes

Rolling Processes


Rod, Wire, and Tube Drawing

Sheet Metal Forming Processes

Introduction and Classification

Shearing Processes

Bending Processes

Stretch Forming

Deep Drawing

Rubber Pad Forming (Flexible-Die Forming)

Hydroforming (Fluid-Forming Processes)


Superplastic Forming of Sheets

Blow Forming and Vacuum Forming

Thermoforming Methods

Sheet Metal Formability

High-Velocity Forming and High-Energy-Rate Forming

Introduction and Classification

Characteristics of HVF and HERF Processes

High-Velocity Forming Machines

High-Energy-Rate Forming Processes

Future of HVF and HERF

Powder Metallurgy and Processing of Ceramic Materials


Historical Development of Powder Metallurgy

Metal Powder Production

Powder Metal Characterization

Blending and Mixing of Powders

Powder Compaction


Secondary Operations

Ceramic Materials

Ceramic Manufacturing Processes

Polymeric Materials and Their Processing


Historical Development of Polymeric Materials


Thermoplastic Polymers (Thermoplastics TP)

Thermosetting Polymers (Thermosets)


Thermoplastic Elastomers

Processing of Polymeric Materials

Composite Materials and Their Fabrication Processes


Classification and Characteristics of Composites

Fiber-Reinforced Composites

Particulate Composite Materials

Laminated Composite Materials

Combinations of Composite Materials

Fabrication of Composite Materials

Molding Processes

Prepreg Fabrication

Filament Winding


Fundamentals of Traditional Machining Processes


Basics of Chipping Processes

Basics of Abrasion Processes

Machine Tools for Traditional Machining


General Purpose Machine Tools

Special Purpose Machine Tools

Fundamentals of Nontraditional Machining Process


Classification of Nontraditional Machining Processes

Jet Machining

Ultrasonic Machining

Chemical Machining

Electrochemical Machining

Electrochemical Grinding

Electric Discharge Machining

Electron Beam Machining

Laser Beam Machining

Plasma Arc Cutting

Concluding Characteristics of NTMPS

Numerical Control of Machine Tools


NC Concepts

Movements in CNC Systems

Control of NC Machine Tools

CNC Machine Tools

Input Units

CNC Instructions

Program Format

Features of CNC Systems

Part Programming

Industrial Robots and Hexapods


Industrial Robots


Surface Technology


Surface Smoothing

Surface Cleaning

Surface Protection

Roll Burnishing and Ballizing


Joining Processes


Fusion Welding

Solid-State Welding

Solid–Liquid State Welding

Welding of Plastics

Metallurgy of Welded Joints

Welding Defects

Welding Quality Control

Mechanical Joining

Advanced Manufacturing Techniques


Near Net Shape Manufacturing

Microfabrication Technology


Semiconductor Device Fabrication

Sustainable and Green Manufacturing

Materials, Processes, and Design for Manufacturing


Function, Material, Process, and Shape Interaction

Manufacturing Process Capabilities

Process Selection Factors

Manufacturing Process Selection

Design for Manufacturing

Quality Control


Statistical Quality Control

Total Quality Control

The ISO 9000 Standard

Dimensional Control

Measuring Quality Characteristics

Measuring Tools and Equipment

Coordinate-Measuring Machine

Surface Measurements

Nondestructive Testing and Inspection

Destructive Testing

Automation in Manufacturing Technology


Mechanization versus Automation

Automation and Production Quantity

Necessity for Introducing Automation

Manufacturing Systems

Flexible Manufacturing Systems

Computer Integrated Manufacturing.

Integrated Manufacturing Production System-Lean Production

Adaptive Control

Smart Manufacturing and Artificial Intelligence

Factory of Future

Concluding Remarks Related to Automated Manufacturing

Health and Safety Aspects in Manufacturing


Health and Safety at Work

Sources of Manufacturing Hazards

Personal Protective Equipment

Hazards of Manufacturing Operations

Appendix A: List of Symbols

Appendix B: Greek Letters

Appendix C: List of Acronyms


About the Authors

Professor Helmi A. A. Youssef, born in August, 1938 in Alexandria, Egypt, acquired his B.Sc. degree with honor in Production Engineering from Alexandria University in 1960. He completed his scientific building in the Carolo-Welhelmina, TH Braunschweig in Germany during the period 1961-1967. In June 1964 he earned his Dipl.-Ing. degree, then in December 1967, he completed his Dr.-Ing. degree in the domain of Non-traditional Machining. In 1968, he returned to Alexandria University, Production Engineering Dept. as an assistant professor. In 1973was promoted to associate, and in 1978 to full professor. In the period 1995-1998, professor Youssef was the chairman of the Production Engineering Dept., Alexandria University. Since 1989, he has been a member of the scientific committee for promotion of professors in Egyptian universities. Between 1975 and 1995, Professor Youssef was a visiting professor in El-Fateh University in Tripoli, the Technical University in Baghdad, King Saud University (KSU) in Riyadh, and Beirut Arab University (BAU) in Beirut. He established laboratories, and supervised many M.Sc. and Ph.D. theses. Professor Youssef has organized and participated in many international conferences. He has published many scientific papers in specialized journals. He has co-authored many books in his fields of specialization, and has been the single author of two books. One book, co-authored on "Machining Technology", has been published in 2008 by CRC, USA. Currently, he is an emeritus professor in PED, Alexandria University.

Professor Hassan El-Hofy was born in 1953, in Egypt. He received a B. Sc Honors degree in Production Engineering from Alexandria University in 1976, and then served as a teaching assistant in the same department and received a M. Sc. in Production Engineering from Alexandria University in 1979. Following M. Sc., he worked as an assistant lecturer until October 1980 when he left to Aberdeen University in Scotland and began his Ph. D. in hybrid machining processes. In 1985, he resumed his work in Alexandria University as an assistant professor. In 1990, he was promoted to an associate professor, and in November 1997 he was promoted to a full professor. Between 2000-2005 he worked as a professor in the University of Qatar where he chaired the accreditation committee for mechanical engineering program toward ABET Substantial Equivalency Recognition. Professor El-Hofy has written several books, including Advanced Machining Processes: Nontraditional and Hybrid Processes (McGraw Hill, 2005), Fundamentals of Machining Processes (CRC Press), and Machining Technology (CRC Press, 2008). He published over 50 scientific and technical papers. He is a Consulting Editor to many international journals and regular participant in international conferences. Between 2007-2010 he was chairman of the Production Engineering Department of Alexandria University.

Professor M. Hamed Ahmed was born in 1947 in Alexandria, Egypt. He received a B.Sc. Degree in Production Engineering, from Alexandria University in 1970, with First Degree of Honors. He obtained a M.Sc. Degree in 1973, after which he was promoted to the position of Assistant Lecturer. In 1978, he earned his Ph.D. from the University of Birmingham, UK. In 1978, he resumed work at Alexandria University as an Assistant Professor. He left Alexandria to work for the UAE University from 1982 to 1987. He was promoted to an Associate Professor at Alexandria University in 1986. He left for King Abdul Aziz University in Saudi Arabia during the period 1997-2002. Besides the long term leave, Professor Ahmed worked as a part time Visiting Professor for the Arab University of Beirut in Lebanon, Qatar University, the Arab Academy for Science and Technology-Alexandria, El-Mansoura University, El-Minia University, and El-Menofeyia University. Alongside his career, Prof. Ahmed planned and taught numerous graduate and undergraduate courses in the general fields of materials and manufacturing. He took part in establishing and developing laboratories in the same fields. Professor Ahmed has supervised numerous M.Sc. and Ph.D. degrees. He has a good track record of publishing in national/international conferences and reputable journals. He also contributed to the development of industrial activities within Alexandria through consultations. Currently; he is an emeritus professor in Production Engineering, Alexandria University

Subject Categories

BISAC Subject Codes/Headings:
SCIENCE / Mechanics / General
TECHNOLOGY & ENGINEERING / Industrial Engineering