Fundamentals of Modern Manufacturing: Materials, Processes, and Systems (7th edition) [7 ed.] 111947521X, 9781119475217

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Fundamentals of Modern Manufacturing Materials, Processes, and Systems Seventh 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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VP AND EDITORIAL DIRECTOR

Laurie Rosatone

EXECUTIVE EDITOR

Don Fowley

EDITOR

Jennifer Brady

EDITORIAL MANAGER

Judy Howarth

CONTENT MANAGEMENT DIRECTOR

Lisa Wojcik

CONTENT MANAGER

Nichole Urban

SENIOR CONTENT SPECIALIST

Nicole Repasky

PRODUCTION EDITOR

Mathangi Balasubramanian

PHOTO RESEARCHER

Thamizhselvi Deivanayagam

COVER PHOTO CREDIT

Courtesy of Kennametal, Inc. and Courtesy of Sandvik Coromant

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PREFACE Fundamentals of Modern Manufacturing: Materials, Processes, and Systems is designed for a first course or two-course sequence in manufacturing at the junior or senior 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 disciplines. Most of the book’s content is concerned with manufacturing processes (about 65% of the text), but it also provides significant 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 covered 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, polymers, and composite materials), (2) its inclusion of recently developed manufacturing processes in addition to the traditional processes that have been used and refined 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 significantly 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 quantitative is based on its emphasis on manufacturing 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 first book on manufacturing processes to provide a quantitative coverage of the topic.



Organization of the Book The first chapter provides an introduction and overview of manufacturing. Manufacturing is defined, and the materials, processes, and systems of manufacturing are briefly described. The final section provides an introduction to manufacturing economics. The remaining 39 chapters are organized into 11 parts. Part I, titled Material Properties and Product Attributes, consists of four chapters that describe the important characteristics of materials and the products made from them. Part II discusses the four basic engineering materials: metals, ceramics, polymers, and composites. Part III begins the coverage of the part-shaping processes, which are organized into four categories: (1) solidification processes, (2) particulate processes, (3) deformation processes, and (4) material removal processes. Part III consists of five chapters on the solidification 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 rolling, 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 nontraditional material removal technologies. iii

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Part VII consists of two chapters on property enhancing processes and surface processing. Property enhancing is accomplished by heat treatment, and surface processing includes operations such as cleaning, electroplating, 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 fit into the preceding classification scheme are covered in Part IX, titled Special Processing and Assembly Technologies. Its five chapters cover additive manufacturing, processing of integrated circuits, electronics assembly, microfabrication, and nanofabrication. 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 flexible manufacturing systems. Finally, Part XI deals with manufacturing support systems: process planning, production planning and control, lean production, and quality control and inspection.



New Content for the Seventh Edition The topical organization of the seventh edition remains pretty much the same as the sixth edition, but several new topics have been added and others have been updated. The following material is new or revised in the seventh edition: Global (Revisions that affect the entire book) • There are more than 1300 review questions, a 67% increase in the total number of review questions compared to the sixth edition. • There are more than 650 problems, a 42% increase in the total number of problems compared to the sixth edition. • There are more than 1500 multiple-choice questions, approximately the same number as in the sixth edition. • The historical notes are back in the book. Instead of making them available to look up on the website for the book, as in the sixth edition, they are imbedded as sidebars in the technical text. Chapter-by-Chapter (Significant revisions of individual chapters) • Chapter 1 Introduction and Overview of Manufacturing: Section 1.5 (Manufacturing Economics) includes expanded coverage of batch production. • Chapter 4 Physical Properties of Materials: Tables 4.1 and 4.2 on physical properties have been updated and expanded. • Chapter 5 Dimensions, Surfaces, and their Measurement: New coverage of area surface measurement techniques has been added to Section 5.4 (Measurement of Surfaces). • Chapter 6 Metals: Expanded coverage of the Bayer process for purifying alumina and the Hall– Heroult process to produce aluminum from alumina in Section 6.3.1 (Aluminum). • Chapter 7 Ceramics: New coverage of zirconia in Section 7.3 (New Ceramics). New subsection on specialty glasses (e.g., Gorilla® Glass) in Section 7.4 (Glass). • Chapter 12 Glassworking: New coverage of the fusion-draw process in Section 12.2.2 (Shaping of Flat and Tubular Glass). New coverage of the ion-exchange process in Section 12.3.1 (Heat Treatment).

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• Chapter 13 Shaping Processes for Plastics: New Section 13.2.4 on Plastic Extrusion Economics. Section 13.6 (Injection Molding) has been revised, and a new Section 13.6.4 on Injection-Molding Economics has been added. • Chapter 15 Powder Metallurgy: New subsection on Powder Metallurgy Economics has been added. • Chapter 19 Sheet Metalworking: New coverage of multi-station pressworking systems has been added in Section  19.4 (Equipment and Economics for Sheet-Metal Pressworking). A new Section 19.4.3 on Economics of Sheet-Metal Pressworking has been added. • Chapter 21 Machining Operations and Machine Tools: Coverage of CNC Machining Centers has been revised and updated. • Chapter 23 Economic and Product Design Considerations in Machining: Section 23.3 (Machining Economics) has been expanded to include considerations of batch production in machining. • Chapter 32 Additive Manufacturing: Section 32.2 (Additive Manufacturing Technologies) has been entirely revised and updated to be consistent with ASTM F2792 and ISO/ASTM 52900 standards. • Chapter 38 Integrated Manufacturing Systems: Section 38.6 (Flexible Manufacturing Systems) has been revised and updated to reflect the recent advances in FMS technology and applications.



New Format for the Seventh Edition The format of the seventh edition has been changed significantly. The new edition is available in several versions. Here is what’s available for students and for instructors who adopt the book: For students: The seventh edition is published in digital format together with an optional paperback version. The digital version contains the following: • The complete unabridged text, including historical notes. • 996 review questions organized by chapter topics, with answers to selected questions to test the student’s understanding of content. • 490 problems organized by chapter topics, with solutions to selected questions to test the student’s understanding of content. • 981 multiple-choice questions organized by chapter topics, with answers to all questions to test the student’s understanding of content. The optional paper-back version is abridged and is intended as a companion copy for the digital edition. It does not contain historical notes, review questions, problems, or multiple-choice questions. For instructors: The seventh edition is available in printed paper-back format intended to be an evaluation copy for instructors to consider for adoption. It contains all of the content in the student digital edition, including review questions, problems, and multiple-choice questions. For instructors who adopt the book for their courses, this printed textbook becomes their desk copy.



Support Material for Instructors The following support materials are available for instructors who adopt Fundamentals of Modern Manufacturing for their courses: • A complete set of PowerPoint Lecture Slides for all chapters is available to instructors for their class lectures. Instructors can decide whether to make these slides available to their students. • For instructors who wish to make their own slides, a complete Image Gallery of all figures in the book is available to instructors.

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• A solutions manual containing answers and/or solutions to all review questions, problems, and multiple-choice questions in the student digital version is available online to instructors who adopt the book. • Additional exercises are also available for instructors to use as homework and/or quizzes at their discretion. These additional exercises consist of 333 review questions, 167 problems, and 535 multiple-choice questions, all with answers and solutions. These support materials for Fundamentals of Modern Manufacturing are available at the website www.wiley.com/go/Groover/FundModernManu7e. Evidence that the book has been adopted as the main textbook for the course must be verified. Individual questions or comments may be directed to the author at [email protected] or [email protected].

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ACKNOWLEDGMENTS This book has been published in six previous editions. I like to believe that each new revision has been an improvement over its predecessor and that this seventh edition is the culmination of these successive improvements. If I indulge myself this belief, it has been made possible by many people who have (1) participated in surveys conducted by the publisher, (2) served as technical reviewers of the book, (3) identified errors in the text, and (4) communicated their opinions and suggestions to me. In all cases, I have appreciated the feedback and would like to acknowledge the individuals for their contributions, apologizing in advance for any unintended omissions. In alphabetical order, with affiliations in parentheses, they are Iftikhar Ahmad (George Mason University), John T. Berry (Mississippi State University), J. T. Black (Auburn University), David Bourell (University of Texas at Austin), Richard Budihas (Voltaic LLC), David Che (Geneva College), Paul Cotnoir (Worcester Polytechnic Institute), John Coulter (Lehigh University), Robert E. Eppich (American Foundryman’s Society), Gayle Ermer (Calvin College), Osama Eyeda (Virginia Polytechnic Institute and State University), Wolter Fabricky (Virginia Polytechnic Institute and State University), Jack Feng (formerly of Bradley University and now at Caterpillar, Inc.), Keith Gardiner (Lehigh University), Jay R. Geddes (San Jose State University), Shivan Haran (Arkansas State University), R. Heikes (Georgia Institute of Technology), Andrew Herzing (Lehigh University), Yong Huang (Clemson University), Ralph Jaccodine (Lehigh University), Marian Kennedy (Clemson University), Aram Khachatourians (California State University, Northridge), Kurt Lesker IV (former student and now president of his family’s company), Steven Liang (Georgia Institute of Technology), Harlan MacDowell (Michigan State University), Wojciech Misiolek (Lehigh University), Barbara Mizdail (Pennsylvania State University—Berks campus), Joe Mize (Oklahoma State University), Amy Moll, (Boise State University), Colin Moodie (Purdue University), Victor Okhuysen (California State Polytechnic University, Pomona), Nicholas Odrey (Lehigh University), Michael Philpott (University of Illinois at Champaign-Urbana), Corrado Poli (University of Massachusetts at Amherst), Chell Roberts (Arizona State University), Anil Saigal (Tufts University), Huseyin Sarper (Colorado State University-Pueblo), G. Sathyanarayanan (Lehigh University), Rajiv Shivpuri (Ohio State University), Larry Smith (St. Clair College, Windsor, Ontario), Malur Srinivasan (Texas A&M University), Brent Strong (Brigham Young University), James B. Taylor (North Carolina State University), Yonglai Tian (George Mason University), Gregory L. Tonkay (Lehigh University), Joel Troxler (Montana State University), Ampere A. Tseng (Arizona State University), Chester VanTyne (Colorado School of Mines), Robert Voigt (Pennsylvania State University), Daniel Waldorf (California State Polytechnic University, San Luis Obispo), Jim Waterman (former student and now Program Manager, Army ManTech Program; and Adjunct Professor, Rowan University), Charles White (GMI Engineering and Management Institute), Marvin White (Lehigh University), and Parviz Yavari (California State University, Long Beach). In addition, I want to express my appreciation to John Wiley & Sons, Inc., for continuing to publish Fundamentals of Modern Manufacturing through its many editions. I have had the pleasure of working with some outstanding professionals at Wiley during the past 20 years; let me acknowledge those who have participated in this seventh edition: Don Fowley (Editorial Director); Jennifer Brady (Editor); Judy Howarth (Content Enablement Manager); and Mathangi Balasubramanian (Production Editor) and her fine staff of copy-editors at Spi-Global. I also wish to acknowledge Shannon Corliss, freelance editor who worked with me at the beginning of this project.

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And finally, I want to acknowledge several of my Lehigh colleagues for their contributions to this and preceding editions: David Angstadt of Lehigh’s Department of Mechanical Engineering and Mechanics; Ed Force II, Laboratory Technician in our George E. Kane Manufacturing Technology Laboratory; Sharon Siegler, Senior Engineering Librarian (retired), Fairchild/Martindale Library; and Marcia Groover, my wife and former colleague at Lehigh University. I sometimes write textbooks about how computers are used in manufacturing, but when my computer needs fixing, she is the one I call on.

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ABOUT THE AUTHOR Mikell P. Groover is Professor Emeritus of Industrial and Systems Engineering at Lehigh University, where he taught and did research for 44 years. He received his B.A. in Arts and Science (1961), B.S. in Mechanical Engineering (1962), M.S. in Industrial Engineering (1966), and Ph.D. (1969), all from Lehigh. His industrial experience includes several years as a manufacturing engineer before embarking on graduate studies at Lehigh. His teaching and research areas include manufacturing processes, production systems, automation, material handling, facilities planning, and work systems. He has received a number of teaching awards at Lehigh University, as well as the Albert G. Holzman Outstanding Educator Award from the Institute of Industrial Engineers (1995) and the SME Education Award from the Society of Manufacturing Engineers (2001). His publications include over 75 technical articles and books (listed below). His books are used throughout the world and have been translated into French, German, Spanish, Portuguese, Russian, Japanese, Korean, and Chinese. The first edition of Fundamentals of Modern Manufacturing received the IIE Joint Publishers Award (1996) and the M. Eugene Merchant Manufacturing Textbook Award from the Society of Manufacturing Engineers (1996). Dr. Groover is a member of the Institute of Industrial Engineers (IIE) and the Society of Manufacturing Engineers (SME). He is a Fellow of IIE and SME.



Previous Books by the Author Automation, Production Systems, and Computer-Aided Manufacturing, Prentice Hall, 1980. CAD/CAM: Computer-Aided Design and Manufacturing, Prentice Hall, 1984 (co-authored with E. W. Zimmers, Jr.). Industrial Robotics: Technology, Programming, and Applications, McGraw-Hill Book Company, 1986 (co-authored with M. Weiss, R. Nagel, and N. Odrey). Automation, Production Systems, and Computer Integrated Manufacturing, Prentice Hall, 1987. Fundamentals of Modern Manufacturing: Materials, Processes, and Systems, originally published by Prentice Hall in 1996, and subsequently published by John Wiley & Sons, Inc., 1999. Automation, Production Systems, and Computer Integrated Manufacturing, Second Edition, Prentice Hall, 2001. Fundamentals of Modern Manufacturing: Materials, Processes, and Systems, Second Edition, John Wiley & Sons, Inc., 2002. Fundamentals of Modern Manufacturing: Materials, Processes, and Systems, Third Edition, John Wiley & Sons, Inc., 2007. Work Systems and the Methods, Measurement, and Management of Work, Pearson Prentice Hall, 2007. Automation, Production Systems, and Computer Integrated Manufacturing, Third Edition, Pearson Education, Inc., 2008. Fundamentals of Modern Manufacturing: Materials, Processes, and Systems, Fourth Edition, John Wiley & Sons, Inc., 2010. Introduction to Manufacturing Processes, John Wiley & Sons, Inc., 2012. Fundamentals of Modern Manufacturing: Materials, Processes, and Systems, Fifth Edition, John Wiley & Sons, Inc., 2013.

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Automation, Production Systems, and Computer Integrated Manufacturing, Fourth Edition, Pearson Education, Inc., 2015. Fundamentals of Modern Manufacturing: Materials, Processes, and Systems, Sixth Edition, John Wiley & Sons, Inc., 2016. History of the Department of Industrial and Systems Engineering at Lehigh University, 1924–2010, Lehigh Preserve, Lehigh University, 2017. Automation, Production Systems, and Computer Integrated Manufacturing, Fifth Edition, Pearson Education, Inc., 2019.

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CONTENTS Content available in eBook  Student solution available in interactive e-text  1

INTRODUCTION AND OVERVIEW OF MANUFACTURING 1

5

1.1 1.2 1.3 1.4 1.5

What Is Manufacturing?  2 Materials in Manufacturing  8 Manufacturing Processes  10 Production Systems  17 Manufacturing Economics  20

5.1

Part I M  aterial Properties and Product Attributes 27 2

THE NATURE OF MATERIALS 27

2.1 2.2 2.3 2.4 2.5

Atomic Structure and the Elements  27 Bonding between Atoms and Molecules  30 Crystalline Structures  32 Noncrystalline (Amorphous) Structures  37 Engineering Materials  38

3

MECHANICAL PROPERTIES OF MATERIALS 40

3.1 3.2 3.3 3.4 3.5

Stress–Strain Relationships  40 Hardness 53 Effect of Temperature on Properties  57 Fluid Properties  59 Viscoelastic Behavior of Polymers  61

4

PHYSICAL PROPERTIES OF MATERIALS  64

4.1 4.2 4.3 4.4 4.5

Volumetric and Melting Properties  64 Thermal Properties  67 Mass Diffusion  69 Electrical Properties  71 Electrochemical Processes  73

DIMENSIONS, SURFACES, AND THEIR MEASUREMENT 75

Dimensions, Tolerances, and Related Attributes 75 5.2 Conventional Measuring Instruments and Gages 76 5.3 Surfaces 84 5.4 Measurement of Surfaces  88 5.5 Effect of Manufacturing Processes  90 Part II Engineering Materials  93 6

METALS 93

6.1 6.2 6.3 6.4

Alloys and Phase Diagrams  94 Ferrous Metals  98 Nonferrous Metals  114 Superalloys 124

7

CERAMICS 126

7.1 7.2 7.3 7.4 7.5

Structure and Properties of Ceramics  127 Traditional Ceramics  129 New Ceramics  131 Glass 134 Some Important Elements Related to Ceramics 138

8

POLYMERS 142

8.1

Fundamentals of Polymer Science and Technology 144 8.2 Thermoplastic Polymers  153 8.3 Thermosetting Polymers  157 8.4 Elastomers 160 8.5 Polymer Recycling and Biodegradability  166

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9

COMPOSITE MATERIALS  169

9.1

Technology and Classification of Composite Materials 170 Metal Matrix Composites  177 Ceramic Matrix Composites  179 Polymer Matrix Composites  180

9.2 9.3 9.4

Part III Solidification Processes  184 10

14

PROCESSING OF POLYMER MATRIX COMPOSITES AND RUBBER  291

14.1 14.2 14.3 14.4 14.5 14.6

Overview of PMC Processing  291 Open-Mold Processes  295 Closed-Mold Processes  299 Other PMC Shaping Processes  301 Rubber Processing and Shaping  305 Manufacture of Tires and Other Rubber Products 310

FUNDAMENTALS OF METAL CASTING  184

10.1 Overview of Casting Technology  186 10.2 Heating and Pouring  188 10.3 Solidification and Cooling  192

Part IV P  articulate Processing of Metals and Ceramics 315

11

METAL CASTING PROCESSES  2