1st Edition

Manufacturing Technology Materials, Processes, and Equipment

    948 Pages 861 B/W Illustrations
    by CRC Press

    948 Pages 861 B/W Illustrations
    by CRC Press

    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.

    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


    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 i

    "…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