CONTENTS
General Introduction 1
1.What Is Manufacturing? 1
2.The Design Process and Concurrent Engineering 6
3.Selecting Materials 11
4.Selecting Manufacturing Processes 13
5.ComputerIntegrated Manufacturing 18
6.Global Competitiveness and Manufacturing Costs 21
7.Lean Production and Agile Manufacturing 22
8.Environmentally Conscious Design and Manufacturing 23
PARTⅠ Fundamentals of Materials:Their Behaviorand Manufacturing Properties
1 The Structure of Metals 29
1.1 Introduction 29
1.2 The Crystal Structure of Metals 30
1.3 Cold,Warm， and HotWorking 31
1.4 Work Hardening (Strain Hardening) 32
1.5 Plastic Deformation of Polycrystalline Metals 32
2 Mechanical Behavior,Testing,and Manufacturing Properties of Materials 37
2.1 Introduction 37
2.2 Tension 38
2.3 Compression 42
2.4 Torsion 43
2.5 Bending(Flexure) 44
2.6 Hardness 45
3 Physical Properties of Materials 51
3.1 Introduction 51
3.2 Density 51
3.3 Melting Point 55
3.4 Specific Heat 55
3.5 Thermal Conductivity 55
3.6 Thermal Expansion 56
3.7 Electrical, Magnetic, and Optical Properties 57
3.8 Corrosion Resistance 58
4 Metal Alloys Structure and Cast Irons 63
4.1 Introduction 63
4.2 Structure of Alloys 64
4.3 The IronCarbon System 67
4.4 Cast Irons 69
5 Ferrous Metals and Alloys 75
5.1 Introduction 75
5.2 Production of Iron and Steel 76
5.3 Carbon and Alloy Steels 79
5.4 Tool and Die Steels 82
6 Nonferrous Metals and Alloys 85
6.1 Introduction 85
6.2 Aluminum and Aluminum Alloys 87
6.3 Magnesium and Magnesium Alloys 88
6.4 Copper and Copper Alloys 90
6.5 Superalloys 91
6.6 Titanium and Titanium Alloys 92
6.7 LowMelting Alloys 93
6.8 Precious Metals 96
6.9 ShapeMemory Alloys 96
6.10 Amorphous Alloys (Metallic Glasses) 97
6.11 Nanomaterials 97
7 Polymers: Structure,General Properties,and Applications 101
7.1 Introduction 101
7.2 The Structure of Polymers 103
7.3 Thermoplastics 108
7.4 Thermosetting Plastics 109
7.5 Additives In Plastics 110
7.6 〖ZK(〗General Properties and Applications of Thermoplastics 111
7.7 〖ZK(〗General Properties and Applications of Thermosetting Plastics 114
7.8 Biodegradable Plastics 115
7.9 Elastomers(Rubbers) 117
8 Composite Materials: Structure,General Properties, and Applications 121
8.1 Introduction 121
8.2 The Structure of Reinforced Plastics 122
8.3 Properties of Reinforced Plastics 126
8.4 Applications of Reinforced Plastics 127
8.5 MetalMatrix Composites (MMC) 130
8.6 CeramicMatrix Composites (CMC) 131
8.7 Other Composites 131
PART Ⅱ Forming and Shaping Processes and Equipment
9 Fundamentals of MetalCasting 135
9.1 Introduction 135
9.2 Solidification of Metals 137
9.3 MetalCasting Processes 140
10 Forging of Metals 157
10.1 Introduction 157
10.2 OpenDie Forging 159
10.3 ImpressionDie and ClosenDie Forging 161
10.4 Extrusion and Drawing 164
11 Processing of Powder Metallurgy 169
11.1 Introduction 169
11.2 Production of Metal Powders 171
11.3 Compaction of Metal Powders 176
11.4 Sintering 177
11.5 Process Capabilities 180
11.6 Economics of Powder Metallurgy 181
12 Forming and Shaping Plastics and Composite Materials 183
12.1 Introduction 183
12.2 Injection Molding 184
12.3 Blow Molding 187
13 RapidPrototyping Operations 191
13.1 Introduction 191
13.2 Additive Processes 192
13.3 Applications of RapidPrototyping Technology 200
PART Ⅲ MaterialRemoval Processes and Machines
14 Fundamentals of Cutting 211
14.1 Introduction 211
14.2 The Mechanics of Chip Formation 214
14.3 The Types of Chips Produced In MetalCutting 216
14.4 Cutting Forces and Power 218
14.5 Tool Life: Wear and Failure 222
14.6 Surface Finish and Surface Integrity 225
14.7 Machinability 227
15 CuttingTool Materials and Cutting Fluids 235
15.1 Introduction 235
15.2 Carbon and MediumAlloy Steels 239
15.3 HighSpeed Steels 239
15.4 CastCobalt Alloys 240
15.5 Carbides 240
15.6 Coated Tools 245
15.7 AluminaBased Ceramics 246
15.8 Cubic Boron Nitride 247
15.9 SiliconNitride Based Ceramics 248
15.10 Diamond 248
15.11 WhiskerReinforced and Nanocrystalline Tool Materials 249
16 Machining Processes Used to Produce Round Shapes 253
16.1 Introduction 253
16.2 Turning Parameters 256
16.3 Lathes and Lathe Operations 259
16.4 〖ZK(〗HighSpeed Machining, Ultraprecision Machining, and Hard Turning 267
16.5 Boring and Boring Machines 270
16.6 Drilling and Drills 272
17 Machining Processes Used to Produce Various Shapes 279
17.1 Introduction 279
17.2 Milling Operations 280
17.3 Milling Machines 289
17.4 Planing and Shaping 292
18 Machining and Turning Centers 295
18.1 Introduction 295
18.2 Machining and Turning Centers 295
18.3 Machining Economics 303
19 Abrasive Machining and Finishing Operations 309
19.1 Introduction 309
19.2 Abrasives 311
19.3 Bonded Abrasives (Grinding Wheels) 313
19.4 Honing 317
19.5 Lapping 318
19.6 Polishing 318
19.7 Electropolishing 319
19.8 Polishing Processes Using Magnetic Fields 319
19.9 Buffing 320
20 Advanced Machining Processes and Nanofabrication 323
20.1 Introduction 323
20.2 Chemical Machining 325
20.3 ElectricalDischarge Machining 327
20.4 Wire EDM 330
20.5 LaserBeam Machining 331
20.6 ElectronBeam Machining and PlasmaArc Cutting 334
20.7 Nanofabrication 335
20.8 Micromachining 337
20.9 Economics of Advanced Machining Processes 338
中英文对照词汇表 343
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