8/13/2019 Pros Man 2014

1/21

Manufacturing Process and

Material Selection

Kalpakjian 2006

8/13/2019 Pros Man 2014

2/21

1.The Structure of Metals

Behavior and Manufacturing Properties of Part I

Crystal Structure of Metals

Permanent Deformation

Defects in a Single-Crystal Lattice

Edge Dislocation Movement

Solidification of Molten Metal

Plastic Deformation of Idealized Grains Recovery, Recrystallization, and Grain Growth Effects

Temperature Ranges for Cold, Warm and Hot Working

8/13/2019 Pros Man 2014

3/21

2.Mechanical Behavior, Testing, and

Manufacturing Properties of Materials

Relative Mechanical Properties of Materials

Tensile-test Specimen and Machine

Tension Test Stress-strain Curve

Mechanical Properties of Materials

Tension and Stress Curves Temperature Effects on Stress-strain Curves

Strain and Deformation Rate in Manufacturing

Hardness-testing Methods and Formulas

S-N Curves

Endurance Limit vs. Tensile Strength

Creep Curve

Material Failures

Temperature Transition in Metals

8/13/2019 Pros Man 2014

4/21

3.Physical Properties of Materials

Physical Properties

Ratio of Maximum Yield Stress to Density

Specific Strength and Stiffness Specific Strength as a Function of Temperature

8/13/2019 Pros Man 2014

5/21

4. Metal Alloys: Structure and Strengthening by

Heat Treatment

Two Phase Systems

Cooling of Metals

Unit Cells

Microstructure of Steel Formed from Eutectoid

Composition Microstructure for Cast Irons

Martensite

Hardness of Tempered Martensite

Hardness and Toughness in Steel as a Function of CarbideShape

Effect of Time and Temperature on Yield Stress

Hardness of Steel as a Function of Carbon Content

8/13/2019 Pros Man 2014

6/21

5. Ferrous Metals and Alloys: Production,

General Properties, and Applications

Casting

Carbon and Alloy Steel Applications

Tool and Die Materials

8/13/2019 Pros Man 2014

7/21

6.Nonferrous Metals and Alloys: Production,

General Properties, and Applications

Cost of Wrought Metals and Plastics vs.

Carbon Steel

Aluminum Alloy Properties

Properties

8/13/2019 Pros Man 2014

8/21

7.Ceramics, Graphite, and Diamond: Structure,

General Properties, and Applications

Ceramic Components

Ceramic Types and Characteristics

Properties of Ceramics

8/13/2019 Pros Man 2014

9/21

8/13/2019 Pros Man 2014

10/21

9.Composite Materials: Structure, General

Properties and Applications

Methods of Reinforcing Plastics

Tensile Strength and Modulus for Fibers in

Plastic

Properties of Reinforcing Fibers

Mechanical Properties of Reinforced Plastics

Metal-Matrix Composite Parts

8/13/2019 Pros Man 2014

11/21

10. Fundamentals of Metal Casting

Solidification of Pure Metals

Cast Structures of Solidified Metals

Basic Types of Cast Structures

8/13/2019 Pros Man 2014

12/21

11. Metal-Casting Processes

Summary of Casting Processes

Typical Cast Parts

Characteristics of Casting

Production Steps in Sand-Casting

Sand Mold Sequence of Operations in Making a Ceramic Mold

Investment Casting Process

Vacuum-Casting

Hot-Chamber Die-Casting

Cold-Chamber Die-Casting Properties and Applications of Die-Casting Alloys

Melt-Spinning

8/13/2019 Pros Man 2014

13/21

12.Metal Casting, Design, Materials, and

Economics

General Design Rules for Casting

Locating and Designing Gates

Design Rules for Casting Shrinkage Allowance for Casting in Sand Molds

Casting Applications and Characteristics

Cost Characteristics of Casting

8/13/2019 Pros Man 2014

14/21

13.Rolling of Metals

Flat-Rolling and Shape-Rolling Processes

Roll Arrangements

Bending of Rolls Effects of Hot Rolling

Thread-Rolling Processes

Machined and Rolled Threads Various Tube-Rolling Processes

8/13/2019 Pros Man 2014

15/21

14.Forging of Metals

Forged Components

Microstructure as a Function of Manufacturing Method

Characteristics of Forging

Cogging Operation on a Rectangular Bar

Impression-Die Forging Forging a Rod, Fullering, and Edging

Force in Impression Die Forging

The Coining Process

Heading

Swaging Metals in Decreasing Order of Forgeability

Principles of Various Forging Machines

Cost-per-piece in Forging

8/13/2019 Pros Man 2014

16/21

15.Extrusion and Drawing of Metals

Direct-Extrusion

Extrusions and Products Made from Extrusions

Types of Extrusion

Process Variables in Direct Extrusion

Extrusion Force

Types of Metal Flow in Extrusion with Square Dies

Extrusion Temperature Ranges

Impact Extrusion

Process Variables in Wire Drawing

Tube-Drawing Operations Drawing Dies

Multistage Wire-drawing Machine

8/13/2019 Pros Man 2014

17/21

16.Sheet-Metal Forming Processes

Characteristics of Sheet-Metal Forming Processes

Shearing with a Punch and Die

Shearing

Die-Cutting Operations

Conventional Versus Fine-Blanking

Slitting with Rotary Knives

The Shaving Process

Shear Angles

Compound Die and Progressive Die

Characteristics of Metals Used in Sheet-Forming

Cupping Test and Bulge-Test

Forming Limit Diagram

Bending Terminology

Minimum Bend Radius

Springback in Bending

Methods of Reducing or Eliminating Springback

Common Die-Bending Operations

Bending Operations

Flanging Operations

Roll-Forming Process

Manufacturing of Bellows

Deep-Drawing

Relationship between Average Normal Anisotropy and the Limiting Drawing Ratio

Bending and Embossing of Sheet Metal

Hydroform Process

Tube-Hydroforming

Explosive Forming

Cymbal Manufacture

Manufacturing Honeycomb Structures

Cost of Conventional Spinning Versus Cost of Deep Drawing

8/13/2019 Pros Man 2014

18/21

17.Processing of Metal Powders

Parts Made by Powder-Metallurgy

Steps in Making Powder-Metallurgy Parts

Particle Shapes in Metal Powders

Mechanical Comminution to Obtain Fine Particles

Compaction

Density as a Function of Pressure and the Effects ofDensity on Other Properties

Compacting Pressures for Various Powders

Sintering Time and Temperature for Metals

Mechanical Properties of P/M Materials

Design Considerations for P/M

8/13/2019 Pros Man 2014

19/21

18.Processing of Ceramics, Glass, and

Superconductors

Characteristics of Ceramics Processing

Steps in Making Ceramic Parts

Doctor-Blade Process

Extruding and Jiggering

Shrinkage of Wet Clay Drawing Process and Rolling Process

Glass Tubing Manufacturing

Steps in Manufacturing Glass Bottles

Manufacturing Glass by Pressing into Mold

Centrifugal Casting of Glass

Powder-In-Tube Process

8/13/2019 Pros Man 2014

20/21

19.Forming and Shaping Plastics and Composite

Materials

Characteristics of Forming and Shaping Processes for Plastics and CompositeMaterials

Forming and Shaping Processes for Plastics, Elastomers, and Composite Materials

Extruder Schematic

Extrusion Die Geometries

Extrusion of Tubes

Melt-Spinning Process

Injection Molding

Blow-Molding

Thermoforming Process

Compression Molding

Transfer Molding

Vacuum-Bag Forming and Pressure-Bag Forming

Open-Mold Processing

Filament-Winding

Production Characteristics of Molding Methods

8/13/2019 Pros Man 2014

21/21

20.Rapid-Prototyping Operations

Characteristics of Additive Rapid-PrototypingTechnologies

Mechanical Properties of Selected Materials for RapidPrototyping

Fused-Deposition-Modeling

Stereolithography

Selective-Laser-Sintering

Three-Dimensional-Printing

Laminated-Object-Manufacturing

Investment Casting Using Rapid-Prototyped Wax Parts