DeGarmo's MATERIALS AND PROCESSES IN MANUFACTURING TENTH EDITION2025|PDF|Epub|mobi|kindle电子书版本百度云盘下载

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Chapter 1 Introduction to DeGarmo’s Materials and Processes in Manufacturing1

1.1 Materials，Manufacturing，and the Standard of Living1

1.2 Manufacturing and Production Systems3

Case Study Famous Manufacturing Engineers27

Chapter 2 Properties of Materials28

2.1 Introduction28

2.2 Static Properties30

2.3 Dynamic Properties42

2.4 Temperature Effects（Both High and Low）47

2.5 Machinability Formability，and Weldability50

2.6 Fracture Toughness and the Fracture Mechanics Approach50

2.7 Physical Properties52

2.8 Testing Standards and Concerns53

Case Study Separation of Mixed Materials55

Chapter 3 Nature of Metals and Alloys56

3.1 Structure-Property-Processing-Performance Relationships56

3.2 The Structure of Atoms57

3.3 Atomic Bonding57

3.4 Secondary Bonds59

3.5 Atom Arrangements in Materials59

3.6 Crystal Structures of Metals59

3.7 Development of a Grain Structure61

3.8 Elastic Deformation62

3.9 Plastic Deformation63

3.10 Dislocation Theory of Slippage64

3.11 Strain Hardening or Work Hardening64

3.12 Plastic Deformation in Polycrystalline Metals65

3.13 Grain Shape and Anisotropic Properties66

3.14 Fracture of Metals66

3.15 Cold Working，Recrystallization，and Hot Working66

3.16 Grain Growth68

3.17 Alloys and Alloy Types68

3.18 Atomic Structure and Electrical Properties68

Chapter 4 Equilibrium Phase Diagrams and the Iron-Carbon System71

4.1 Introduction71

4.2 Phases71

4.3 Equilibrium Phase Diagrams71

4.4 Iron-Carbon Equilibrium Diagram79

4.5 Steels and the Simplified Iron-Carbon Diagram80

4.6 Cast Irons82

Case Study The Blacksmith Anvils88

Chapter 5 Heat Treatment89

5.1 Introduction89

5.2 Processing Heat Treatments89

5.3 Heat Treatments Used to Increase Strength92

5.4 Strengthening Heat Treatments for Nonferrous Metals93

5.5 Strengthening Heat Treatments for Steel96

5.6 Surface Hardening of Steel109

5.7 Furnaces112

5.8 Heat Treatment and Energy114

Case Study A Carpenter’s Claw Hammer116

Chapter 6 Ferrous Metals and Alloys118

6.1 Introduction to History-Dependent Materials118

6.2 Ferrous Metals118

6.3 Iron119

6.4 Steel120

6.5 Stainless Steels132

6.6 Tool Steels134

6.7 Alloy Cast Steels and Irons136

Case Study Interior Tub of a Top-Loading Washing Machine138

Chapter 7 Nonferrous Metals and Alloys139

7.1 Introduction139

7.2 Copper and Copper Alloys140

7.3 Aluminum and Aluminum Alloys144

7.4 Magnesium and Magnesium Alloys152

7.5 Zinc-Based Alloys154

7.6 Titanium and Titanium Alloys155

7.7 Nickel-Based Alloys157

7.8 Superalloys and Other Metals Designed for High-Temperature Service157

7.9 Lead and Tin，and Their Alloys158

7.10 Some Lesser Known Metals and Alloys159

7.11 Metallic Glasses159

7.12 Graphite160

Case Study Nonsparking Wrench161

Chapter 8 Nonmetallic Materials：Plastics，Elastomers，Ceramics，and Composites162

8.1 Introduction162

8.2 Plastics163

8.3 Elastomers173

8.4 Ceramics175

8.5 Composite Materials182

Case Study Two-Wheel Dolly Handles194

Chapter 9 Material Selection195

9.1 Introduction195

9.2 Material Selection and Manufacturing Processes197

9.3 The Design Process199

9.4 Procedures for Material Selection200

9.5 Additional Factors to Consider203

9.6 Consideration of the Manufacturing Process204

9.7 Ultimate Objective205

9.8 Materials Substitution207

9.9 Effect of Product Liability on Materials Selection207

9.10 Aids to Material Selection208

Case Study Material Selection212

Chapter 10 Measurement and Inspection and Testing213

10.1 Introduction213

10.2 Standards of Measurement214

10.3 Allowance and Tolerance220

10.4 Inspection Methods for Measurement227

10.5 Measuring Instruments229

10.6 Vision Systems for Measurement238

10.7 Coordinate Measuring Machines240

10.8 Angle-Measuring Instruments240

10.9 Gages for Attributes Measuring242

10.10 Testing245

10.11 Visual Inspection247

10.12 Liquid Penetrant Inspection247

10.13 Magnetic Particle Inspection248

10.14 Ultrasonic Inspection250

10.15 Radiography252

10.16 Eddy-Current Testing253

10.17 Acoustic Emission Monitoring255

10.18 Other Methods of Nondestructive Testing and Inspection256

10.19 Dormant versus Critical Flaws257

Case Study Measuring An Angle261

Chapter 11 Fundamentals of Casting262

11.1 Introduction to Materials Processing262

11.2 Introduction to Casting263

11.3 Casting Terminology265

11.4 The Solidification Process266

11.5 Patterns276

11.6 Design Considerations in Castings278

11.7 The Casting Industry280

Case Study The Cast Oil-Field Fitting282

Chapter 12 Expendable-Mold Casting Processes283

12.1 Introduction283

12.2 Sand Casting283

12.3 Cores and Core Making298

12.4 Other Expendable-Mold Processes with Multiple-Use Patterns302

12.5 Expendable-Mold Processes Using Single-Use Patterns304

12.6 Shakeout，Cleaning，and Finishing310

12.7 Summary310

Case Study Movable and Fixed Jaw Pieces for a Heavy-Duty Bench Vise312

Chapter 13 Multiple-Use-Mold Casting Processes313

13.1 Introduction313

13.2 Permanent-Mold Casting313

13.3 Die Casting316

13.4 Squeeze Casting and Semisolid Casting320

13.5 Centrifugal Casting322

13.6 Continuous Casting324

13.7 Melting325

13.8 Pouring Practice328

13.9 Cleaning，Finishing，and Heat Treating of Castings329

13.10 Automation in Foundry Operations330

13.11 Process Selection330

Case Study Baseplate for a Household Steam Iron333

Chapter 14 Fabrication of Plastics，Ceramics，and Composites334

14.1 Introduction334

14.2 Fabrication of Plastics334

14.3 Processing of Rubber and Elastomers346

14.4 Processing of Ceramics347

14.5 Fabrication of Composite Materials351

Case Study Fabrication of Lavatory Wash Basins362

Chapter 15 Fundamentals of Metal Forming363

15.1 Introduction363

15.2 Forming Processes：Independent Variables364

15.3 Dependent Variables366

15.4 Independent-Dependent Relationships366

15.5 Process Modeling367

15.6 General Parameters368

15.7 Friction and Lubrication under Metalworking Conditions369

15.8 Temperature Concerns371

Case Study Repairs to a Damaged Propeller380

Chapter 16 Bulk Forming Processes381

16.1 Introduction381

16.2 Classification of Deformation Processes381

16.3 Bulk Deformation Processes382

16.4 Rolling382

16.5 Forging389

16.6 Extrusion401

16.7 Wire，Rod，and Tube Drawing406

16.8 Cold Forming，Cold Forging，and Impact Extrusion409

16.9 Piercing413

16.10 Other Squeezing Processes414

16.11 Surface Improvement by Deformation Processing416

Case Study Handle and Body of a Large Ratchet Wrench420

Chapter 17 Sheet-Forming Processes421

17.1 Introduction421

17.2 Shearing Operations421

17.3 Bending430

17.4 Drawing and Stretching Processes437

17.5 Alternative Methods of Producing Sheet-Type Products451

17.6 Pipe Welding451

17.7 Presses452

Case Study Fabrication of a One-Piece Brass Flashlight Case459

Chapter 18 Powder Metallurgy460

18.1 Introduction460

18.2 The Basic Process461

18.3 Powder Manufacture461

18.4 Rapidly Solidified Powder（Microcrystalline and Amorphous）463

18.5 Powder Testing and Evaluation463

18.6 Powder Mixing and Blending463

18.7 Compacting464

18.8 Sintering468

18.9 Hot-Isostatic Pressing469

18.10 Other Techniques to Produce High-Density P/M Products470

18.11 Metal Injection Molding（MIM）or Powder Injection Molding（PIM）471

18.12 Secondary Operations473

18.13 Properties of P/M Products475

18.14 Design of Powder Metallurgy Parts476

18.15 Powder Metallurgy Products478

18.16 Advantages and Disadvantages of Powder Metallurgy478

18.17 Process Summary480

Case Study Impeller for an Automobile Water Pump483

Chapter 19 Electronic Electrochemical Chemical and Thermal Machining Processes484

19.1 Introduction484

19.2 Chemical Machining Processes485

19.3 Electrochemical Machining Processes504

19.4 Electrical Discharge Machining510

Case Study Fire Extinguisher Pressure Gage522

Chapter 20 Fundamentals of Machining/Orthogonal Machining523

20.1 Introduction523

20.2 Fundamentals524

20.3 Energy and Power in Machining533

20.4 Orthogonal Machining（Two Forces）538

20.5 Merchant’s Model542

20.6 Mechanics of Machining（Statics）543

20.7 Shear Strain γ and Shear Front Angle？545

20.8 Mechanics of Machining（Dynamics）547

20.9 Summary556

Case Study Orthogonal Plate Machining Experiment at Auburn University559

Chapter 21 Cutting Tools for Machining560

21.1 Introduction560

21.2 Cutting-Tool Materials565

21.3 Tool Geometry577

21.4 Tool Coating Processes578

21.5 Tool Failure and Tool Life582

21.6 Flank Wear583

21.7 Economics of Machining588

21.8 Cutting Fluids591

Case Study Comparing Tool Materials Based on Tool Life597

Chapter 22 Turning and Boring Processes598

22.1 Introduction598

22.2 Fundamentals of Turning，Boring，and Facing Turning600

22.3 Lathe Design and Terminology607

22.4 Cutting Tools for Lathes614

22.5 Workholding in Lathes619

Case Study Estimating the Machining Time for Turning627

Chapter 23 Drilling and Related Hole-Making Processes628

23.1 Introduction628

23.2 Fundamentals of the Drilling Process629

23.3 Types of Drills631

23.4 Tool Holders for Drills643

23.5 Workholding for Drilling645

23.6 Machine Tools for Drilling645

23.7 Cutting Fluids for Drilling649

23.8 Counterboring，Countersinking，and Spot Facing650

23.9 Reaming651

Case Study Bolt-down Leg on a Casting655

Chapter 24 Milling656

24.1 Introduction656

24.2 Fundamentals of Milling Processes656

24.3 Milling Tools and Cutters663

24.4 Machines for Milling669

Case Study HSS versus Tungsten Carbide Milling676

Chapter 25 Workholding Devices for Machine Tools677

25.1 Introduction677

25.2 Conventional Fixture Design677

25.3 Design Steps680

25.4 Clamping Considerations682

25.5 Chip Disposal683

25.6 Unloading and Loading Time684

25.7 Example of Jig Design684

25.8 Types of Jigs686

25.9 Conventional Fixtures688

25.10 Modular Fixturing690

25.11 Setup and Changeover691

25.12 Clamps694

25.13 Other Workholding Devices694

25.14 Economic Justification of Jigs and Fixtures698

Case Study Fixture versus No Fixture in Milling701

Chapter 26 Numerical Control（NC）and the A（4）Level of Automation702

26.1 Introduction702

26.2 Basic Principles of Numerical Control710

26.3 Machining Center Features and Trends721

26.4 Ultra-High-Speed Machining Centers（UHSMCs）725

26.5 Summary726

Case Study Process Planning for the MfE730

Chapter 27 Other Machining Processes731

27.1 Introduction731

27.2 Introduction to Shaping and Planing731

27.3 Introduction to Broaching736

27.4 Fundamentals of Broaching737

27.5 Broaching Machines742

27.6 Introduction to Sawing743

27.7 Introduction to Filing751

Case Study Cost Estimating—Planing vs.Milling755

Chapter 28 Abrasive Machining Processes756

28.1 Introduction756

28.2 Abrasives757

28.3 Grinding Wheel Structure and Grade763

28.4 Grinding Wheel Identification767

28.5 Grinding Machines771

28.6 Honing780

28.7 Superfinishing781

28.8 Free Abrasives783

Case Study Overhead Crane Installation789

Chapter 29 Thread and Gear Manufacturing790

29.1 Introduction790

29.2 Thread Making795

29.3 Internal Thread Cutting-Tapping798

29.4 Thread Milling803

29.5 Thread Grinding805

29.6 Thread Rolling805

29.7 Gear Making808

29.8 Gear Types811

29.9 Gear Manufacturing812

29.10 Machining of Gears813

29.11 Gear Finishing821

29.12 Gear Inspection823

Case Study Bevel Gear for a Riding Lawn Mower826

Chapter 30 Fundamentals of Joining827

30.1 Introduction to Consolidation Processes827

30.2 Classification of Welding and Thermal Cutting Processes828

30.3 Some Common Concerns828

30.4 Types of Fusion Welds and Types of Joints829

30.5 Design Considerations832

30.6 Heat Effects832

30.7 Weldability or Joinability839

30.8 Summary840

Chapter 31 Gas Flame and Arc Processes842

31.1 Oxyfuel-Gas Welding842

31.2 Oxygen Torch Cutting846

31.3 Flame Straightening848

31.4 Arc Welding849

31.5 Consumable-Electrode Arc Welding851

31.6 Nonconsumable-Electrode Arc Welding859

31.7 Welding Equipment864

31.8 Arc Cutting865

31.9 Metallurgical and Heat Effects in Thermal Cutting867

Case Study Bicycle Frame Construction and Repair870

Chapter 32 Resistance and Solid-State Welding Processes871

32.1 Introduction871

32.2 Theory of Resistance Welding871

32.3 Resistance Welding Processes874

32.4 Advantages and Limitations of Resistance Welding879

32.5 Solid-State Welding Processes879

Case Study Field Repair to a Power Transformer888

Chapter 33 Other Welding Processes，Brazing and Soldering889

33.1 Introduction889

33.2 Other Welding and Cutting Processes889

33.3 Surface Modification by Welding-Related Processes898

33.4 Brazing901

33.5 Soldering909

Chapter 34 Adhesive Bonding，Mechanical Fastening，and Joining of Nonmetals915

34.1 Adhesive Bonding915

34.2 Mechanical Fastening924

34.3 Joining of Plastics927

34.4 Joining of Ceramics and Glass929

34.5 Joining of Composites929

Case Study Golf Club Heads with Insert932

Chapter 35 Surface Engineering933

35.1 Introduction933

35.2 Mechanical Cleaning and Finishing Blast Cleaning940

35.3 Chemical Cleaning946

35.4 Coatings948

35.5 Vaporized Metal Coatings958

35.6 Clad Materials958

35.7 Textured Surfaces959

35.8 Coil-Coated Sheets959

35.9 Edge Finishing and Burrs959

35.10 Surface Integrity961

Case Study Dana Lynn’s Fatigue Lesson967

Chapter 36 Quality Engineering969

36.1 Introduction969

36.2 Determining Process Capability970

36.3 Inspection to Control Quality981

36.4 Process Capability Determination from Control Chart Data985

36.5 Determining Causes for Problems in Quality986

36.6 Summary996

Case Study Boring QC Chart Blunders1000

Index1001