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Manufacturing Processes & Materials Manufacturing Processes & Materials George F. Schrader Ahmad K. Elshennawy Society of Manufacturing Engineers Dearborn, Michigan iv Manufacturing Processes & Materials Copyright © 2000 by Society of Manufacturing Engineers Based on Manufacturing Processes and Materials for Engi- neers previously published by Prentice-Hall, Inc. 987654321 All rights reserved, including those of translation. This book, or parts thereof, may not be reproduced by any means, includ- ing photocopying, recording or microfilming, or by any infor- mation storage and retrieval system, without permission in writing of the copyright owners. No liability is assumed by the publisher with respect to use of information contained herein. While every precaution has been taken in the preparation of this book, the publisher assumes no responsibility for errors or omissions. Publication of any data in this book does not constitute a recommendation or endorsement of any patent, proprietary right, or product that may be involved. Library of Congress Catalog Card Number: 00-131494 International Standard Book Number: 0-87263-517-1 Additional copies may be obtained by contacting: Society of Manufacturing Engineers Customer Service One SME Drive, P.O. Box 930 Dearborn, Michigan 48121 1-800-733-4763 www.sme.org SME staff who participated in producing this book: Millicent Treloar, Senior Editor Rosemary Csizmadia, Production Supervisor Frances Kania, Production Assistant Kathye Quirk, Production Assistant/Cover Design Cover photo courtesy of Precision Balancing & Analyzing Co., Machine Tool Spindle Repairs & New Spindles Printed in the United States of America v Manufacturing Processes & Materials About the Authors About the Authors Co-authors George F. Schrader and Ahmad K. Dr. Elshennawy, currently an Associate Pro- Elshennawy have the wealth of practical expe- fessor in the Department of Industrial Engineer- rience and technical knowledge of manufactur- ing and Management Systems at the University ing processes necessary for the compilation of a of Central Florida, has an educational back- comprehensive text on the subject. ground in production engineering and industrial Dr. Schrader, currently Professor of Engi- engineering. Since 1978 he has taught many neering, Emeritus, at the University of Central courses on manufacturing and manufacturing- Florida in Orlando, has an educational back- related subjects at Alexandria University in ground in mechanical engineering, applied math- Egypt, Pennsylvania State University, and the ematics, and industrial engineering. Since 1945 University of Central Florida. Dr. Elshennawy’s he has taught a variety of courses and coordi- greatest expertise is in the area of precision mea- nated laboratory exercises on the subject of surement and manufacturing automation, sub- manufacturing at several major universities in ject areas in which he acquired considerable the U.S. In addition to his academic work, he experience while working at the National Insti- has served as a consultant to many manufactur- tute of Standards and Technology (NIST) in ing industries and worked with a number of tech- Gaithersburg, Maryland. nical societies on industry-related activities. vii Manufacturing Processes & Materials Table of Contents Table of Contents 1 MANUFACTURING FOUNDATIONS 1.1 Manufacturing .......................................................................................................1 1.2 Hand Tools to Machine Tools...................................................................................1 1.2.1 Early Hand Tools, 1.2.2 The Iron Age, 1.2.3 Industrial Revolution, 1.2.4 Automation 1.3 Types of Products....................................................................................................5 1.4 Organization for Manufacturing ..............................................................................5 1.4.1 Types of Manufacturing Systems, 1.4.2 Small Organizations, 1.4.3 Large Organizations, 1.4.4 Manufacturing Engineering 1.5 Questions ............................................................................................................10 2 THE COMPETITIVE CHALLENGE IN MANUFACTURING 2.1 Importance of Manufacturing as an Economic Activity ............................................13 2.2 State of the Industry ..............................................................................................13 2.3 Labor Productivity .................................................................................................14 2.4 International Competitiveness ...............................................................................16 2.4.1 Balance of Trade, 2.4.2 Trade Agreements 2.5 Manufacturing Innovations ...................................................................................18 2.5.1 Machine Tools, 2.5.2 Manufacturing Systems 2.6 Questions ............................................................................................................21 3 MATERIAL PROPERTIES AND TESTING 3.1 Metal Structures ...................................................................................................23 3.1.1 Unit Cells, 3.1.2 Changes in Crystal Structure, 3.1.3 Crystalline Structure and Physical Properties, 3.1.4 Fracture 3.2 Fundamentals of Metal Alloys ...............................................................................27 3.2.1 Metallic Solid Solutions and Compounds, 3.2.2 How Alloys Melt, 3.2.3 Equilibrium Diagrams, 3.2.4 Alloys in the Solid State, 3.2.5 Grain Growth 3.3 Metallurgy of Iron and Steel ..................................................................................33 3.3.1 Iron and Iron Carbide Solid Solutions, 3.3.2 Pearlite, 3.3.3 Hypoeutectoid and Hypereutectoid Steels, 3.3.4 Martensite, 3.3.5 Other Structures of Steel, 3.3.6 Practical Aspects of Carbon in Steel, 3.3.7 Grain Size of Steel, 3.3.8 Solidification of Cast Iron 3.4 Testing of Engineering Materials ............................................................................38 3.4.1 Tension Test, 3.4.2 Hardness Testing, 3.4.3 Notched-bar Impact Testing, 3.4.4 Bend Tests, 3.4.5 High-temperature Tests, 3.4.6 Fatigue Testing, 3.4.7 Fracture Toughness Tests, 3.4.8 Nondestructive Testing, 3.4.9 Corrosion Testing 3.5 Questions ............................................................................................................52 3.6 Problems .............................................................................................................53 viii Manufacturing Processes & Materials Table of Contents 4 IRON AND STEEL 4.1 Iron, Steel, and Power ..........................................................................................57 4.2 Iron Making .........................................................................................................57 4.3 The Blast Furnace and its Chemistry ......................................................................59 4.4 Steelmaking .........................................................................................................59 4.4.1 The Basic Oxygen Process, 4.4.2 The Electric-furnace Process 4.5 Finishing and Ingot Teeming .................................................................................64 4.6 Special Techniques in Steel Refining.......................................................................65 4.7 Aluminum............................................................................................................65 4.8 Copper ...............................................................................................................66 4.9 Miscellaneous Metals............................................................................................68 4.9.1 Magnesium, 4.9.2 Zinc, 4.9.3 Lead, 4.9.4 Tin, 4.9.5 Titanium, 4.9.6 Tungsten 4.10 Steel ..................................................................................................................69 4.11 Effects of Alloying Elements in Ferrous Alloys ........................................................69 4.12 Carbon Steels ....................................................................................................71 4.13 Alloy Steels ........................................................................................................72 4.14 Questions ..........................................................................................................76 5 NONFERROUS METALS AND ALLOYS 5.1 Effects of Alloying on Properties.............................................................................79 5.2 Aluminum............................................................................................................80 5.2.1 Aluminum Alloys 5.3 Magnesium .........................................................................................................81 5.3.1 Magnesium Alloys 5.4 Copper ...............................................................................................................83 5.4.1 Copper Alloys 5.5 Zinc.....................................................................................................................84 5.5.1 Zinc Alloys 5.6 Titanium ..............................................................................................................85 5.6.1 Titanium Alloys 5.7 Nickel and its Alloys .............................................................................................86 5.8 The White Metals .................................................................................................86 5.9 Refractory Metals .................................................................................................86
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